Rust Bend

After removing the rusted metal, I try to duplicate the structure of the material that was removed, which can be a little like putting a puzzle back together. I used a basic hammer forming technique and sandwiched a piece of 18 gauge between some four inch square structural tubing and a bit of flat stock. Notice the nice radius on the structural steel; I will duplicate this in my sheet metal by working the metal over the corner with the chunk of aluminum, or "corking tool". The flat stock on top of the sandwich holds the work as I hammer it over the edge. The end result is all that matters--be creative with the tools or shapes you have laying around to get there.

1989 Pontiac Formula - Corrosion Cure

After removing the rusted metal, I try to duplicate the structure of the material that was removed, which can be a little like putting a puzzle back together. I used a basic hammer forming technique and sandwiched a piece of 18 gauge between some four inch square structural tubing and a bit of flat stock. Notice the nice radius on the structural steel; I will duplicate this in my sheet metal by working the metal over the corner with the chunk of aluminum, or "corking tool". The flat stock on top of the sandwich holds the work as I hammer it over the edge. The end result is all that matters--be creative with the tools or shapes you have laying around to get there. View Related Article