I recently seen an ad in a magazine advertising these.It looks like you can fill in rust holes by just spraying over the hole.I have always cut out the rust and welded in new metal.Seems to me the rust would just come back, if done the way they claim.Has anyone tried one of these spray welders,and what do you think of them?

http://www.rustbusters.com/

It sounds good. I heard on another board of a guy who had some paint issues later on with the areas treated,but that could be anything.

Well I don't see much technical info beyond:

"By spraying pure metal onto the surface, filling in rust holes while also galvanizing the area, the problem is solved. The metal bonds mechanically at approximately 40,000 lbs. PSI, and can be applied as fine as .001 thousands of an inch to 1 foot thick.

Rust holes of any size can be fixed, yet the process is slow enough that the surface temperature only reaches 100° F. which avoids warping."

So the claim is some type of welding/galvanizing that can be .001" thick, bonds at 40,000 PSI and only reaches 100 degrees? Sounds too good to be true to me.

I would really "like" for it to be true, but I would sure want to witness it on someone elses project and $$ before I turned over my hard earned dough!

Maybe someone else can chime in and say, "it works great" and give some more details, till then, I'll remain a skeptic.

I remain sceptical also.I guess its something you have to see in person.The one I seen ads for was a Metco Plasma Spray,looks impresive but I don't think Its price is to friendly.

I have seen some of this stuff in practice at Strip-it, here in Michigan. It feels solid to the knuckle, it is not for structural areas, and it costs about $100.00 per hour to put on. The piece I saw was a sample on an old hood that had rusted out along the front crown. Finished off in primer it looked great and when you turned it ove there was the support frame of the hood all rusted through.

I have a couple of spots on my '66 that I am considering. I will wait till my guy from the body shop gives me a price to repair first, before I will have it metal sprayed. A neat alternative to sheetmetal.

Mike

We've used spray welding at work to "build up" expensive shafts that have worn (then re-machine). But, I've never heard of using it on rust ... Wouldn't think you'd have much better luck than trying to MIG through rust.