How to Repair Severe Body Rust?

[McBrynlee]

Use a grinder to sand the rusted area, spray some expanding foam, trim off excess foam, wipe clean, and apply a layer of rust inhibitor. Cut a piece of fiberglass mesh, mix resin adhesive with hardener, and apply with a brush. After the adhesive dries, use a grinder to smooth the edges. After sanding, apply body filler, sand with sandpaper, and proceed with painting.

[StQuinn]

I've seen many rust issues with cars. As a car enthusiast who often does DIY repairs, I've found that dealing with body rust requires a step-by-step approach. First, assess the extent: small rust spots only need sanding, applying rust remover, and then touch-up paint; severe rust requires cutting out the corroded parts, welding in new steel plates, followed by primer and topcoat. Tools needed include an angle grinder, rust-proof paint, and a spray gun. Safety first—wear gloves and a mask to avoid inhaling dust. Prevention is key—regularly wash the car and apply wax to prevent moisture. DIY repairs can save a lot of money, but if you lack experience, it's best to watch tutorial videos or ask a knowledgeable friend for help. Don't delay—once rust spreads, repairs become more expensive and troublesome.