Repair of through corrosion damage and holes (Mazda 6 GG)

Using a sanding disc or wire attachment clamped in the chuck of an electric drill, remove all traces of paint from the damaged area and an area about 3 cm wide around it. If you do not have access to a drill, the job can be done just as effectively by hand with sandpaper.

After removing the paint, you can assess the extent of metal damage from corrosion and determine whether it makes sense to begin repairs or whether it would be wiser to replace the entire panel (if this is possible in principle). New panels can be purchased not as expensively as many car enthusiasts believe. It is often much faster and even more economical to install a new panel than to repair extensive damage to the body.

Remove all body trim elements from the damaged panel, except those that can serve as a guide for recreating the original shape of the deformed areas (such as headlight trim, etc.). Using metal shears or a hacksaw blade, remove any loose, weak, or hopelessly corroded metal. Then use a hammer to bend the edges of the hole inward to create a recess that will be filled with filler material.

Use a wire brush to remove powdery rust from the damaged metal. If the back of the damaged area is accessible, treat it with a corrosion inhibitor.

Before you start filling, the hole must be plugged. This can be done by riveting or screwing a piece of tin to the damaged area from the back side, or by covering the hole with wire mesh.

Once the hole is closed, the damaged area can be filled and painted.

[The full text is on the website: mazbook]