HOW TO REPAIR RUST Fender Patch Panel "STACK A TACK" MIG Welding TECHNIQUE 

I'm 77 and I learn something every time I watch your videos. See even old dogs can learn new tricks. Thanks

When I was 15 back in the mid 70's my Dad entered me in a competition as from the age of 13 was doing body work repairing rust. You had to choose the repair you was going to do. My choice that most people won't know unless from the UK was a Hillman Hunter front head light wing repair. What ever you did would have to paint and finish both sides! I was so proud to win being the only teenager and all judges picked the wrong side. No it didn't make me a big head just pushed me to be better at the next repair, and boy was it a ride people expecting perfection every time.

When you're capable of the super awesome perfectionist work, it's easy to leave the "real people" repairs behind. Thanks for keeping your channel down to earth, and sharing all the great tips & tricks for the regular stuff, along with the ultra-slick Kustom work. Great channel!

This is the type of video I love!

Karl, this is so spot on for the DIY guy and what are real world types of repair.. Can't say enough about what you do, how you share so freely, and the skills you bring to the channel. This episode is a real good lesson on rust repair, that I for one can apply to the project in my shop.. Thanks.

I was half-expecting the old "cut-n-butt" here as a part of your "stack a tack". Looks good.

Thank you for teaching us your skill. Love metal work. Learning all the time.

Absolute minute you brought the patch over to the roller & it became apparent there was a no-go on using it, I got enthused bigtime, because I knew what THAT meant. 🤩🤩🤩🤩🤩🤩

Body by Fisher, nice work

Good Timing! I recently thought I should continue my "regular people stuff" project that I have neglected for far too long. Thank you very much for refreshing the theory - now I have to do the practice...

Great video. I love how your videos are unscripted, you are taking us along the repair journey with no BS, just sharing your knowledge. Thank you.

You have the best tips and videos when it comes to sheetmetal work! Thank you

Dude, you are amazing ! "Saving Classic Cars, One patch Panel at a time" !

PERFECT! as I've come to expect with your work Karl. You are also a great teacher of your trade Mate. Thanks always for sharing your talent. Cheers. Billy J.... Queensland, Australia.

Another great video and super relevant. I really appreciate the “regular guy” approach - makes complex problems a lot less daunting and opens the hobby up even more. Thank you

One of my favorite episodes to date!

Really nice job on the patch panel! Take care

You are a true fab rat , in the most respectful way , for a guy of your age it's amazing how you get it done with sometimes homemade tools, it's a pleasure to watch your brain work

Your work is jaw dropping, i'm in awe every time i watch your videos. keep them coming.

I’m so glad I found you on here. The simple approach to fixing cars using basic tools we have in our garage is exactly what I need. I’m a trim carpenter by trade and we do quite a bit of custom work. It’s interesting to see the crossover in fabrication. The way you explain how to do things makes perfect sense in my mind. Working with metal is a whole new world for me, and seeing you break things down and explain them make me feel like I can handle the curveballs this ‘75 El Camino we inherited is throwing at us! I love working with my hands, and stepping into this world of metal work feels like I should have done this decades ago! Thank you so much for making videos that even a regular guy in a small garage with basic tools can breathe life back into this project. With your help, we are bringing the Elky back to life! 🙏

I enjoy all of your videos but these types of videos we can all learn from and put to use. Thanks man .

I am a sheet metal idiot and watching you do your thing is really helpful. I am in the process of restoring a 1953 Citroen so this is all great grain for the mill. Thanks again for sharing your process. Super useful

Awesome and Excellent!! I never would have thought of that intermediate step of sanding the tacs to see the highs n lows. Thank you!!

'I can forsee this taking a very long time...' (Me... Bursts out laughing!!)

I like watching any of your videos but yeah the rust repair and body working videos are the most relatable for me. But don’t hold back on those builds because they are just bad ass!

Always a good refresher to see meticulously metal work. This summer I have a rusty spot on my Mustang to fix.

Karl, you are gifted! Thank you for generously sharing your expertise with us. Much appreciated!

It makes it so much harder when patch panels aren’t exactly the same as the originals, like body lines being a little different and slightly in the wrong spot. I’ve replaced a lot of cab corners on old ford trucks and it can be an absolute crap shoot depending on the reproduction panel. It’s like their stamping dies are completely worn out sometimes and just don’t get the definition they should have.

Love these regular guy type videos. I’ve learned so much from them!

Glad to hear that you're going to do some sheetmetal work every week. Love it how you make it so "simple"!

Very good job .. I live in Nova Scotia I follow "Fitzee's Fabrications" he is a genius at making/installing repair panels to the point where 0 body fill is needed ...

Your workmanship is second to none , thank you for the time you put in to explain the why and wherefore behind every move . I'm always in awe of your patience and careful craftsmanship. Till I tune in again , Stuart in Ontario ..

This is sorely needed Carl.

Nice work Karl, especially fixing the 'loose' replacement panel die lines.

love your work Karl. Tuning in from Aus. Make it a point to watch your content and share it with my car nut mates here in Melbourne Australia.

I am looking at buying what some would call a rust bucket, then fixing it myself as a daily driveer. All this 0 technique, tips and tricks, will help me in bringing it back! Thanks dude!

When someone I consider to be a master metal fabricator does a video on common repairs we all can use, it's time to pay attention. Only wish it was as easy to do as it is to watch, but it certainly makes it less scary for us hobby level car folks.

Your Sheetmetal work is awesome and your just as good explaining the process too! Thanks from VA!

Beautiful, I never get tired of watching magic being performed.

Young man, I'm here to let you know that y'all have some very, very knowledgeable fabricators on y'alls side of the border, and believe you me you're definitely one of the best!!! I envy y'alls beautiful land ;but, There's ABSO-DAWG-GONE-LUTLEY NO WAY I COULD EVER LIVE THERE!!! I live in North Carolina and sometimes that's not far enough South; cause, These old bones move slow and i suspect there gonna start moving slower when i hit the big 60 years young!!! Keep up the great work and videos when you have the time!!!God Bless y'all,sincerely. Joe C.

I've benn fabricating and installing marble and granite countertops for over 20 years. Seeming two pieces of stone together works roughly the same as with metal. Now try getting the two pieces level with each other but match the color, grain and veins of a stone. It was cool seeing how much it relates to stone work. The getting things even "enough" to weld and body fill. Thanks for the video.

Awesome work, Karl. Thanks for the video.

Great repair, wouldn't even be able to tell it's been repaired, thanks for sharing, all the best to you and your loved ones

Nice work dude looks real nice ! A tricky repair I’d say …and I would say that if I was doing it 🤣

This video is exactly what I want to see. Thanks Karl.

Amazing skills! I could watch your videos all day.

Man, I'm so grateful for your willingness to share your techniques in such great detail as well as things you've developed like the really effective tools you have built. Obviously different ecosystems, but you're up there with Ron Covell in terms of value of your content.

Very nice! Always a treat watching you do patches. 👍👍👍

Look forward to seeing you finish the underside components.

This was a great video. I have 1956 Chevy truck that has the same rust spots on the eyebrow of the fender. I look forward to seeing you make the other side from scratch.

Impressive work, and entertaining! You're 100% correct, those types of rust repairs are exactly what I'll be working on........some day!

Nice 👍

Well done, simple and interesting. It's the little tweaks that make it work. Thank you.

Great job on that fender, thank you for the lesson on that type of repair.

Awesome repair. I finally just got my first welder today. Now I can finally practice some of the skills you have taught me!

Want to see more work on the Zephyr and Model A. Love the Zephyr project.

Carl, might I make a suggestion Bud.... if you picked up a couple roles of a Taylor's Measuring tape! Or fabric measuring tape, as it's made of fabric itself it allows you to roll over and edge, such as in this video, you were trying to measure how far back you wanted to mark to cut old material out. You wanted to measure from inside light bucket, up around fender brow and back to spot to mark out your line! Fabric tape will wrap around edge to give you an exact measurement to transfer to replacement peice...

Great teaching video! Gonna have to do some patching on my '58 Plymouth Suburban. Have you considered putting an air line on your welding wand? That way, you just have another little button to push and cool your weld.

Enjoy watching your craftsmanship, always learn something useful in your vids TY

I always pick up a little something from every video. Thanks!

Very nice work as always! Newbies, just because you didn't see welds getting cooled down inbetween grinding doesn't mean it didn't happen! Grinding will produce enough heat to warp panels so keep it cool. An airline blowing cold (like Karl did when welding) will help keep warping to a minimum hopefully.

I recently repaired a couple 55 Chevy fenders with about the same rust. To make relatively sure I had the patch in the same spot I measured from the leading edge and made a couple deep scribe lines to use as a reference before I trimmed anything so I would at least have them in the same position that the original was. Measure twice cut once an old carpenter told me lol.

Most people have no idea how long and the amount of work it really takes to do work like this karl makes it look easy

Good stuff Karl! Edit: I wouldn't have known where to start, it was great to see how / where You did and why.

Excellent video! I am going to be doing something just like this on the rear taillight section on my 1964 Chevelle. Thanks for your video!

👊👊👊 brother i owe you huge!! Always learn lots from ya and stoked to have you doing this for my project

I enjoy and learn from everyone of your videos sir. Keep up the great work.

seriously man, you own the metal.

nice work, great music for easy watching

Love the work. Enjoying these bodywork and sheetmetal videos.

Thanks Karl great video as always your craftsmanship even with basic tools is absolutely and incredible ❤

Nice fitment and advice on this looking forward too seeing the next video and seeing how you make the other pieces thumbs up 👍👍👍👍

Thank you. Love seeing some rust repairs.

Awesome work!!!

You are a great teacher. I wait all week just to see the next video.

Always interesting how much massaging some of those patch panels need. Good work!

Beautiful work !

Love this! Thanks so much for sharing your knowledge!

You're getting better good work.

Keep at it dude. Love the channel - so inspiring,

You've got some great tools. I love doing this kind of stuff, but haven't had the need or opportunity in a long time. Once I retire I'll probably take on some projects.

Harf arsed resto guy here. I've tried to do similar things. That just turn out quite as on point...😆. I keep on trying. It takes such a long time to develop skills and complete the job.

You teach me something every video thank you Carl

Great vid! Love your work, being a powertrain and chassis engineer it’s very inspiring for me!

Thanks for the tips & advice

Hah! "Regular people stuff." Um, I'm a regular guy in my garage and this is grand! Wish you shared this a year ago when I was patching lower front fenders on my '46 Business Coupe! Your expertise and how you share it with us is remarkable and well received. I just keep learning with every one of your videos! Go Japhands, keep moving forward!

great job , I have used those rust repair panels and they are a good starting place but need a little tune up to fit right, 30 years ago I thought that making an offset flange and overlapping the metal then welding was best. It worked ok and was strong but I couldn't get it perfect. the good thing is that it was usually cab corners and that is less obvious than the top of a fender. I have learned so much watching you work, thanks.

Fantastic work as always

Thanks for the lesson.

It's a joy to watch you work. Thanks.

Thanks for your knowledge on doing this. Great stuff keep it coming!!

really keen to see how you fix the inner section where the bucket mounts.

Great work!

Thanks for the tips, they really help.

Enjoy these videos I always learn something from it.

Well done. Love these video as I learn a ton

This is perfect as myself and my dad will be restoring a 58 custom 300 that needs the same work done.

I appreciate all the knowledge I take away from your videos. Thank you!

I love seeing the success you're having. This is great stuff!

Karl you’re the best. Thank you for sharing your talent. 💯👊👍