I show how to repair penetrating rust on the body of an unwelded car.

#### 4. **Patch Any Holes (Without Welding)**

For holes, use a **fiberglass repair kit**:

* Apply the adhesive resin and fiberglass cloth as directed.
* Layer until the hole is sealed and the patch is strong.
* Let it cure fully before moving to the next step.

#### 5. **Apply Body Filler**

Spread body filler (like Bondo) over the area with a plastic spreader, smoothing it as much as possible. Let it harden completely, then sand it down using 80 and 120-grit sandpaper to shape it.

Follow up with 220- and 400-grit for a smooth finish that blends with the rest of the panel.

#### 6. **Prime the Area**

Mask off surrounding areas and spray with automotive primer to create a solid base. Apply multiple light coats and let it dry completely.

#### 7. **Paint and Clear Coat**

Use matching touch-up paint to spray the area in thin, even coats. Let each layer dry before applying the next. Finish with 2–3 layers of clear coat for protection and shine.

> **Pro Tip:** Always blend slightly into the surrounding paint to make the repair less noticeable.

#### 8. **Polish for a Smooth Finish**

After the paint fully cures (usually 24–48 hours), lightly polish the area with a rubbing compound for a smooth, even look.

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### 🚘 **Why This Method Works**

* **No welding needed**
* **Affordable** and uses easily available materials
* **Restores appearance and prevents further rusting**
* **Great for DIY car maintenance** and extending vehicle life

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## Final Thoughts

Repairing penetrating rust without welding is not only possible—it’s **practical and effective**. With patience, the right tools, and a bit of elbow grease, you can stop rust in its tracks and give your car a new lease on life.

So if you’re facing rust damage, don’t panic—and don’t rush to the body shop just yet. Try this method and see how satisfying a successful DIY repair can be!

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Want a printable checklist or video guide to follow along with this repair? Let me know—I’d be happy to help you with that too!