How to Repair Large Hole in Car Body

Step 1: Safety First

Before you begin, put on safety glasses and gloves to protect yourself from flying debris and chemicals. Park your car in a well-ventilated area, and disconnect the battery.

Step 2: Prepare the Hole

Use a wire brush to remove any rust or debris from the edges of the hole. Then, sand the area around the hole to create a smooth surface for the patch.

Step 3: Cut the Patch

Cut a piece of sheet metal that is slightly larger than the hole. The patch should be made of the same type of metal as the car body.

Step 4: Apply Adhesive

Apply a layer of adhesive to the edges of the hole and the back of the patch. Use a spreader to evenly distribute the adhesive.

Step 5: Install the Patch

Place the patch over the hole and press down firmly. Use a hammer and dolly to shape the patch to the contours of the car body.

Step 6: Weld the Patch

Use a welder to weld the patch to the car body. Be sure to use a low heat setting to avoid warping the metal.

Step 7: Grind the Weld

Once the weld is cool, grind it down smooth. Use a sander to smooth out the area around the patch.

Step 8: Paint the Patch

Apply a primer to the patch and the surrounding area. Then, paint the patch to match the rest of the car body.

Tips:

• If the hole is too large to repair with a single patch, you may need to use multiple patches.
• Be sure to use a strong adhesive that is designed for automotive use.
• If you are welding the patch, be sure to use a low heat setting to avoid warping the metal.
• Once the patch is installed, be sure to paint it to protect it from rust.