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How to repair holes in old rusted metal outdoor chair

I was given my grandmothers old (maybe 90 years old) metal outdoor rocking chair (it appears to be sheet metal). It is badly rusted and there are areas where the metal is crumbling away. I wanted to know how to repair the chair to make it safe to use again.

Kimberly Morton
homeowner - Boardman, Ohio
2004

When sheet metal has rusted and is gone, it's gone. You would need to replace the sheet metal or, at the least, go to a weld shop to have a replacement patch of sheet metal welded on. It is probably theoretically possible to connect a sheet metal replacement patch with epoxy, but I don't think I'd try. Then the whole chair needs to be sanded, primed, and painted.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
2004

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