How to Repair a Rust Spot on a Frigidaire Refrigerator

ID: 207209

Description: [youtubevideo|lq5B-guVvNA]Water that leaks from...

Steps:

1. Unplug the refrigerator from the wall outlet.
2. Always work on an unplugged appliance to avoid electrical hazards.
3. Tape the ice maker and water supply lines away from the rusted section to keep the workspace clear.
4. Wear safety goggles and gloves before cutting.
5. Score a rectangle around the rust leaving a two-to-three-inch margin with a rotary cutting tool and metal blade.
6. Keep the blade shallow because the cabinet skin is very thin and separated from the foam.
7. Expect sparks from the rotary tool and keep flammable materials clear.
8. Lift off the cut panel and any loose rust with needle nose pliers.
9. Refrigerant pipes usually run vertically behind the rust trail.
10. Slow down when the rust is deepest because the copper line can be closest to the surface there.
11. Stop cutting as soon as solid metal is clear to prevent piercing the refrigerant circuit.
12. Inspect the cavity; ice-filled foam feels hard and reads cold on an IR camera.
13. Let the unit sit unplugged until the foam softens; overnight is usually enough.
14. A low-heat hair dryer or steam gun can speed thawing but must be kept on the coolest setting.
15. Dig out dark, soggy insulation until only dry, light-colored foam remains.
16. Press on questionable areas; if water oozes out, remove that section too.
17. Expand the excavation as far as six to nine inches if moisture persists to prevent future rust.
18. Measure clearance and maintain roughly a quarter-inch gap between the pipe and the future back panel plane.
19. Gently push the pipe inward with a rubber mallet, wooden dowel, or fingers if it touches the metal.
20. Avoid kinking or stressing the copper line while repositioning.
21. Shake a can of moisture-resistant low-expansion spray foam as directed.
22. Insert the nozzle behind the pipe and fill the space from back to front in slow passes.
23. Leave the foam undisturbed until fully cured, about four hours for most products.
24. Cut excess foam level with the surrounding cabinet using a serrated knife.
25. Work slowly so fresh foam is not pulled from the cavity.
26. Cut a flat sheet of closed-cell insulation to match the opening size.
27. Press the sheet into the cavity so it sits flush without overlapping the factory metal skin.
28. Run a continuous bead of silicone sealant around the perimeter of the new foam sheet.
29. Tool the bead smooth to eliminate air gaps and improve adhesion.
30. Cover the repair with overlapping strips of foil HVAC tape.
31. Press each strip firmly with a putty knife to lock the adhesive and remove air pockets.
32. Reconnect any lines moved earlier and plug the refrigerator back in.
33. Operate the unit for at least one week while monitoring the patched area with touch or an IR camera.
34. A successful repair shows the patch warmer than surrounding metal, confirming external cooling has stopped.