The experts at Muscle Car Restorations show the proper way to repair a rust area on the cowl of a 1973 Dodge Charger using simple fabrication techniques and modest tools.
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00:00 Look and assess the amount of damaged area you have.
00:09 Make a template using masking tape and a razor blade.
00:12 The tape is easily transferred from the vehicle to your new metal.
00:16 Mark out your break lines before you remove the tape.
00:30 Cut out your new patch piece.
00:33 Put a break in it at the line.
00:36 Use a duckbill clamp and a vice to make your final break with a small top edge.
00:50 Drill out your spot welds.
00:52 Cut out the damaged material from your top layer.
00:55 Use a wire wheel to expose the rusty layer underneath.
01:20 Repeat the template making procedure using masking tape and a razor blade.
01:49 Cut and remove the second layer of rusty damaged material.
01:54 Smooth it all out and grind it.
02:12 Smooth out all old spot welds and remove rusty debris material.
02:16 We like to use a 3M belt file to do this.
02:20 Don't forget to apply weld through primer.
02:26 Position the patch panel in place, tack weld and then weld it solid.
02:52 Remove welds on your lower patch panel so you have a seamless repair.
03:03 Apply weld through primer once again.
03:09 Adjust the top patch for fitment.
03:12 Once you are happy, click it into place, tack weld it, weld the seams, make sure you cool
03:19 your welds down so it does not warp.
03:36 Drill your plug weld holes in original spot weld locations.
03:41 Weld and grind smooth.
03:46 Grind smooth all welds avoiding the sheet metal.
03:49 If done correctly, you will have an original looking repair.
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