Rust can wreak havoc on vehicles, undermining their structural integrity and decreasing value. Determining whether major rust repairs are worth the time depends on a number of factors.
Surface rust typically manifests itself in bumps and nicks on body panels, and can easily be resolved using color-matched touch-up paint and rust converter products.
Paint
If the rust damage is limited to surface paint that has bubbled, fixing it with spray can touch-up paint is usually straightforward. Otherwise, grinding off rusted areas and applying rust inhibitor may work; both options cost significantly less than replacing an affected panel but neither are long-term fixes.
Surface rust occurs on the outer layers of your vehicle and often manifests itself after it has been hit or scratched, making treatment easy and less serious than holes or squishy metal that might require full panel replacement.
Before applying touch-up paint, however, you’ll first need to clean the area thoroughly. A good auto parts store will likely recommend an industrial cleaner; or an alcohol wipe and mineral spirits may suffice in eliminating grease or oil that has made its way onto metalwork’s surface. Before beginning, however, make sure the area is completely dry as any moisture left on bare metal surfaces could lead to flash rusting that manifests itself as small spots of rust over time.
After cleaning and wiping the area down with a tack cloth, it’s time to mask it to protect surrounding areas from spray. Poly sheeting works well as it can be cut to fit your repair area perfectly; you will also need tape, mineral spirits, 40-grit sandpaper, a sanding block, and lint rag. Make sure the leading edge of the poly sheeting is taped several feet away so it allows plenty of room for you to blend the touch-up in with what already exists around it.
Before beginning to repair a surface with spray can paint, sand any rust spots to bare metal with an electric sander, expanding as necessary so as to blend them seamlessly with adjacent painted areas. Finally, wet-sand the repaired area to smooth further and prepare for spray can paint application.
Before spraying color onto metal, use a lacquer primer to seal and provide a base for it. Let it set until it dries to touch (at least an hour), before sanding again using 120 and 220 grit sandpaper respectively.
Body Filler
Cracked body panels of your car leave exposed metal that is susceptible to weathering and corrosion. Repairing these flaws with filler will prevent further blemishes from worsening while making the vehicle appear like new again. At AutoZone, they carry top brands like Bondo and Evercoat body filler products so you can find one suitable for your project.
Filler products typically come in standard, medium and premium grades; all three variants utilize polyester resin mixed with cream hardener that adheres to both bare metal and primer surfaces. Which filler you select depends on the size and scope of your work; standard grade works best for filling holes or pinholes while premium fillers work better on larger surface areas or actual tears.
Putty should be mixed and applied according to product instructions, using either a plastic spreader or steel ruler for even coverage. Once dry, rough it up with coarse sandpaper so paint adheres securely; for larger repairs use fine-grit paper for this step to assess how you’re progressing and maintain evenness between additions of filler.
Some body fillers are designed to adhere quickly and effortlessly, which can save time and hassle, especially if dealing with small holes in the bodywork. Still, it’s recommended that after sanding down your patch you prepare the surrounding area thoroughly with primer for best results.
If you’re undertaking a large-scale project, using traditional metal repair products could ensure long-lasting and resilient repairs. These durable repairs typically use higher quality resins that are designed to withstand more abuse than standard putty while remaining easy to sand once set compared with body filler – some even allow cutting with knives once set!
Rust Converter
Iron or steel exposed to moisture undergoes electrochemical oxidation, leading to the familiar reddish-brown substance commonly known as rust. Rust weakens metal, over time leading to serious structural damage; to stop its further corrosion a rust converter solution can be applied – an inert primer layer can then be painted over for long term protection from further corrosion and rust formation.
Eastwood’s Rust Converter comes in both spray and gel forms for effortless application to iron or steel surfaces. For best results, make sure your surface is free from dirt, oil, grease and other contaminants before applying the converter – loose rust can be removed using wire brushing or sandpaper; just take care not to take it down to bare metal as this could interfere with its adhesion and adhesion of the product. The product should only be applied at temperatures between 50 – 95 degrees F for optimal results.
Apply rust converter using a brush (your car’s touch up paint may include one). Thin coats should be applied and left to dry for 15 minutes between applications; as it reacts with the rust it will take on its characteristic purplish black hue.
Once converted, the surface can be primed and then painted with oil based paint to seal and protect it from rain, sunlight and salt spray for longer. This will provide additional resistance against raindrops, sunlight and salt spray exposure than if the rust had not been treated first.
This rust repair solution is ideal for smaller areas of rusted metal that need repairing. While it cannot be used on bare metal, rust converter can help repair medium to severe areas with flaking rust by knocking it away with a wire brush before applying the product.
Sanding
Rust damage on car bodies is fairly common, and usually easy to rectify if caught early. But rust that penetrates into its frame can become dangerous and threaten structural integrity – though modern cars are designed to withstand such damage without significant consequences; however if further rust damage appears and holes form it becomes much more expensive to fix.
For serious rust damage, removal and welding in new patch panels will likely be required. Although this is a difficult job, most reputable auto shops should be capable of accomplishing it successfully. A quality welder is essential here so the welding will hold body filler or coatings securely in place after welds have been completed; once this step has been completed you must treat all exposed metal surfaces with high quality self-etching primer as well as any anticorrosion materials normally employed when fixing late model vehicles.
Once all rust has been eliminated, the new area must be sanded and buffed to match its surrounding paint. This process requires time and skill; therefore it should be performed by professionals for best results.
Sanding provides an ideal opportunity to apply a coat of wax or other protection to newly repainted surfaces, sealing them from moisture entering and starting to eat away at base metals. When taking this task on yourself, ensure you wear safety goggles and leather work gloves to protect both eyes and hands during this process of sanding away paint and rust.
Once you have sanded a surface, be sure to wipe down and remove any remaining rust with automotive degreaser. After this step is completed, spray an even coat of primer over any exposed metal surfaces and allow it to dry according to manufacturer recommendations. When completely dry, lightly sand with fine-grit sandpaper before wiping clean with alcohol and applying another coat of primer as directed by manufacturer instructions.