How to Fix My Rusted Hatch

Cut the damaged area out of the hatch with a jigsaw or hacksaw if the rust has created a hole or severely weak spot. A hacksaw will work well if the damage is on an edge. A jigsaw with a metal cutting blade will work for damage away from an edge.

Use a power sander to smooth the damaged area or the edges of a the cut. There should be no rust or rough spots remaining.

If needed, cut a metal patch with a hacksaw. The patch should be able to fit within the cut hole. If you did not have to cut away the damaged area , you will not need the patch. Instead, skip to the next step.

Add the hardener to the fiberglass resin according to the instructions on the packaging. Mix ratios will depend on the brand. Mix the two substances together. Work swiftly from this point on as this mix will harden quickly.

Spread the resin and hardener mix over a fiberglass mat that was supplied with the fiberglass kit. Create a thin, smooth layer.

Use heavy duty scissors to cut the fiberglass mat to a size that will fully cover the hold and about an inch of the surrounding area.

Place the fiberglass mat over the hole and the surrounding area. Smooth the mat with the flat plastic piece supplied with the kit.

Allow the resin to dry. Dry resin will be hard and smooth like plastic.

Sand the hardened resin and fiberglass mat with a power sander until it is flush with the hatch surface.

Paint the hatch if desired. Use a spray paint that is rust proof and meant for use on metallic surfaces.