Repair rusted out metal post

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Old 08-04-19, 10:50 AM
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Question Repair rusted out metal post

I have a very rusted railing I'm going to rehab, but am unsure how to fill/cover a small section that is open (see picture). Any suggestions? Everything feels very solid, so this appears to be just a cosmetic issue for the moment.

Thanks,
Josh

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Last edited by PJmax; 08-05-19 at 04:53 PM. Reason: reoriented picture
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Old 08-04-19, 01:31 PM
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That's more than cosmetic, maybe stuff with bondo but it's going to be short term!

Remember, rust never sleeps!
 
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Old 08-05-19, 02:40 AM
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Bondo will work for awhile, the cleaner you get the metal the longer it will last.
Ideally you'd replace. It's difficult to weld up rusty metal.
 
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Old 08-05-19, 04:48 AM
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I would clean up the edges of the broken area with an angle grinder to get down to smooth, shiny metal. Then weld the hole shut with repeated beads of weld. Then come back with the angle grinder to create the round shape.
 
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Old 08-05-19, 02:02 PM
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Thanks for the suggestions!
 
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