Bare Knuckle Customs
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Classic car rust repair

Welding and rust repair

Rot cut out and new metal let in, or a panel replaced where a repair won't hold. Welding for classic cars, campers, Land Rovers and vans near Braintree, Essex.

Rust doesn't get better under paint. It comes out, back to clean steel, and new metal goes in.

A shell on a rotisserie turned on its side, the floor pan in red oxide

Repair or replace

  • Cut out and let in. Rot in one patch is cut out and new steel welded in. The rest of the panel stays.
  • A new panel. Where the rot has spread or the panel is thin all over, a new one goes on.

We'll show you what we find and which we'd do before any work starts.

A front suspension turret in an Escort's engine bay, afterA front suspension turret in an Escort's engine bay, before
A rotted turret, cut out, let in with new steel and primed. Drag across to see it.
A new piece of steel welded into a 911 sill

Where rust hides

Sills, arches, door bottoms, floor pans and anywhere water sits behind trim. On campers, the front panel, cab floor and window seams too. On Land Rovers, the steel bulkhead and chassis rust while the alloy panels look fine.

Primer and guide coat over a repaired camper panel

Protecting the repair

New metal is primed and seam sealed, and box sections get cavity wax after paint, or the rust comes back from inside.

Before you buy a project

Send us photos of the sills, arches and floor before you buy. It's easier to price the rust before it's yours.

Questions people ask

Can rust be painted over?

No. Rust carries on under the paint and comes back through it. It has to be cut back to clean steel and new metal let in, or the panel replaced.

Should a rusty panel be repaired or replaced?

If the rot is in one patch, it can be cut out and a new piece welded in. If it has spread or the panel is thin all over, a new panel is the job that lasts.

Where do classic cars rust?

Sills, wheel arches, door bottoms, floor pans, boot floors and anywhere water sits behind trim. Campers add the front panel, cab floor and window seams, and Land Rovers the steel bulkhead and chassis.