Rust Repair & Patch Panels Metalworking Workshop Class

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Below is a brief synopsis of rust repairs done to the headlight eyebrow of a late 1950’s Mopar (Chrysler/Dodge/Plymoth/DeSoto) using six simple hand tools – torch, snips, hammer, dolly, slapper, and slide hammer. This project was done in our excellent 2-day Rust Repair/Patch Panel workshop.

The size of the rust damage is determined, and the Meco welding torch is set for cutting and the offending eyebrow is cut off.
Paper pattern shows size of metal needed to replace and contour of the edge
New sheet of metal is formed, adjusted, marked, and trimmed.
New piece is welded and hammered to fit.
Eyebrow contour needs shrinking at the lead edge. This is done with a hammer and dolly.
Turning the flange with a hammer and dolly and a little heat to adjust the contour.
Checking the chrome headlamp door to make sure the fit is perfect. Total time to complete the whole project was 3 hours.