How to Use a Stud Welder Gun to Repair Your Vehicle's Body and Prevent Rust Damage

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How to Use a Stud Welder Gun to Repair Your Vehicle's Body and Prevent Rust Damage

9 May 2016
 Categories: Construction & Contractors, Articles

Dents and damage in your vehicle's body are not only unattractive, but when not repaired, can lead to the formation of rust. With the right tools and a little bit of knowledge, you can do the repairs properly and remove dents from your vehicle's body yourself. Here are instructions to help you pull dents from your vehicle's body to prepare it for repainting.

Remove Paint and Primer

Before you can repair the dents in your vehicle body, you need to sand off the paint and primer from the dent and at least four to six inches around the damage. When welding studs onto your vehicle's body to pull out the dents, the stud welding gun needs to come in contact with your vehicle's bare metal to create a weld. Use a rough 80-grit sandpaper to remove the paint and primer from the area. 

This type of rough grit sandpaper can leave scratches in the body of your vehicle, but after you have repaired the dent, you can smooth these scratches from the metal for a seamless finish to your vehicle's body.

Weld Studs

Weld the metal pins onto the damaged section of your vehicle, using a stud welding gun and metal pins approximately one-and-a-half inches long. To do this, place a pin in the end of the gun and press the end of the gun onto your vehicle until it connects with your vehicle's body. Pull the trigger to start the electric current in the tip of the gun, which will weld the pin onto the metal body. 

Continue welding metal pins onto your vehicle, spacing them approximately three-fourths of an inch apart from one other. You do not need to weld the pins to the metal in any order, just make sure to weld them over all the dents and wrinkles on your vehicle's area of damage.

Repair Damage

Next, you can pull the dents out of your vehicle's body using a slide hammer. The slide hammer helps you to grab onto the end of each metal pin to pull and smooth the metal on the vehicle's body. To successfully pull out a dent, it is necessary to pull the pins in a specific order: first, pull on the pins welded onto the outside of the damage, working your way into the center of the damage to pull on those pins last. 

After you have repaired the dents, cut the pins from the vehicle's body using a pair of wire cutters. Then, to remove the pin nubs from the vehicle, grind them off using an electric grinder. Be careful not to grind onto the body of your vehicle, as this can damage the metal by grinding it too thin or heating the metal and causing it to warp.

Prepare for Primer and Paint

To cover any remaining wrinkles in your vehicle's body, you can apply a layer of automotive filler onto the area. Use a plastic spreader to smooth it on as much as possible. Allow the filler to dry, then sand the surface smooth, using a coarse 80-grit sandpaper, followed by a fine 180-grit sandpaper. Be sure to also sand the surrounding exposed metal to smooth away any scratches from when you sanded off the paint and primer. 

To completely remove all scratches and create a smooth surface, use a 300-grit or finer sanding block to finish the area. Hold the sanding block with both hands to move the block back and forth in deliberate and even movements. Using a sanding block approximately 12 inches long helps you evenly smooth the entire repair area to get a uniform finish. This will also reveal any high or low spots on the surface of your vehicle, helping you to smooth those out, as well. 

Use this information to repair your vehicle's body and prepare it to be repainted. To find the stud welding supplies you need, visit a website like

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