Rust is a notorious enemy for car owners. Seeing those familiar orange-brown spots creeping across your vehicle’s bodywork is disheartening. If left unchecked, rust can significantly devalue your car and lead to more serious structural problems. While modern cars have improved rustproofing compared to older models, they are still vulnerable, especially in areas exposed to road salt and moisture. One common area prone to rust is the car wing, also known as the fender. Fortunately, minor rust on your car wing is something you can tackle yourself, saving a significant amount compared to professional body shop repairs. This guide will walk you through the process of how to repair rust on your car wing, step-by-step, ensuring a durable and aesthetically pleasing result.
Why Repair Rust on Your Car Wing Yourself?
You might be wondering if DIY rust repair is worth the effort. The answer is a resounding yes, especially when it comes to saving money. Professional rust repair, particularly at a body shop, can be expensive. Labor costs and specialized equipment contribute to bills that can easily run into hundreds, if not thousands, of dollars, especially if multiple panels are affected. By taking on the repair yourself, you primarily pay for materials, which are a fraction of the cost. Furthermore, repairing rust promptly prevents it from spreading and causing more extensive damage, which would ultimately lead to even higher repair costs down the line. This proactive approach not only saves you money but also prolongs the life and appearance of your vehicle.
However, it’s important to be realistic about the extent of the rust. This guide focuses on surface rust, meaning corrosion that hasn’t eaten through the metal and compromised the structural integrity of the car wing. If you are dealing with significant rust-through, holes, or structural damage, it’s best to consult a professional. Similarly, achieving a factory-perfect paint finish, especially with metallic paints, can be challenging for DIYers. For solid colors, you can achieve excellent results. If you are unsure about painting, you can complete the rust removal and preparation stages and then have a body shop handle the painting for a professional finish.
Identifying the Type of Rust on Your Car Wing
Before you begin the repair, it’s crucial to identify the type of rust you’re dealing with. As mentioned earlier, this guide is for surface rust. Surface rust is characterized by orange or brown discoloration on the surface of the metal. It may appear as small spots or larger patches, but the metal underneath is still solid. You can usually confirm surface rust by tapping the affected area; it should sound solid, not hollow or papery.
Structural rust, on the other hand, is more severe. It involves rust that has penetrated deep into the metal, weakening its structure. Signs of structural rust include:
- Rust-through: Visible holes in the metal.
- Flaking or bubbling paint: Paint lifting away from the surface due to rust underneath.
- Soft or weak metal: The affected area feels soft or easily crumbles when touched.
- Hollow sound: Tapping the rusted area produces a hollow or papery sound.
If you suspect structural rust, it’s crucial to seek professional help. Repairing structural rust often requires welding and more extensive bodywork, which is beyond the scope of a typical DIY repair. Attempting to repair structural rust without the proper skills and equipment can compromise the safety and integrity of your vehicle.
Tools and Materials for Car Wing Rust Repair
To effectively repair surface rust on your car wing, you’ll need to gather the right tools and materials. Here’s a comprehensive list:
- Safety Gear:
- Safety glasses: To protect your eyes from rust particles and debris.
- Gloves: To protect your hands from chemicals and sharp edges.
- Dust mask or respirator: To avoid inhaling dust and fumes, especially when sanding and spraying primer/paint.
- Rust Removal Tools:
- Angle grinder with flapper discs: For efficient removal of heavier rust. Start with a coarser grit (e.g., 40 or 60 grit) and move to finer grits.
- Wire brush: For removing loose rust and reaching into tight areas.
- Sandpaper: Various grits (e.g., 80, 120, 240, 320, 400, 600 grit) for progressively smoothing the repair area.
- Sanding block: To ensure even sanding and prevent creating uneven surfaces.
- Rust Treatment and Repair Materials:
- Rust converter: To neutralize any remaining rust and prevent it from spreading. Choose a quality rust converter that chemically reacts with rust.
- Body filler (Bondo): To fill in any imperfections and create a smooth surface.
- Fibreglass epoxy gel (optional): For reinforcing larger or slightly deeper rust areas before applying body filler.
- Finishing Materials:
- Automotive primer: To create a base for paint adhesion and improve paint durability. Use an automotive-specific primer.
- Automotive base coat paint: Matching your car’s color code for a seamless finish. You can find your car’s color code on a sticker, often located on the driver’s side doorjamb or in the glove compartment.
- 2K clear coat: To protect the base coat paint and provide a glossy finish. 2K clear coat is more durable than 1K clear coat.
- Masking tape and paper: To protect surrounding areas from overspray.
- Tack cloth: To remove dust and debris before painting.
- Cleaning and Preparation Materials:
- Mineral spirits or degreaser: To clean the repair area and remove grease, wax, and contaminants.
- Rags: For cleaning and applying products.
- Rubbing compound (optional): For polishing and blending the repaired area with the surrounding paint after clear coat application.
- Polishing pads and machine (optional): For more effective polishing and buffing.
Step-by-Step Guide: Repairing Rust on Your Car Wing
Now that you have gathered your tools and materials, let’s proceed with the step-by-step rust repair process on your car wing.
Step 1: Preparation and Safety
- Clean the car wing: Wash the car wing thoroughly with soap and water and dry it completely. This will remove dirt and debris, allowing you to assess the rust damage accurately.
- Mask off the surrounding area: Use masking tape and paper to protect the areas around the rust from sanding and overspray. Mask a generous area to avoid any accidental damage to the surrounding paint.
- Wear safety gear: Put on your safety glasses, gloves, and dust mask or respirator before proceeding with rust removal.
Step 2: Rust Removal
- Initial rust removal: Start by using a wire brush to remove loose rust flakes and debris from the affected area.
- Grinding (for heavier rust): If the rust is more substantial, use an angle grinder with a flapper disc. Begin with a coarser grit (e.g., 60 grit) to aggressively remove the rust. Work in smooth, overlapping strokes, being careful not to grind into the surrounding good metal. Keep the grinder moving to avoid overheating the metal.
- Sanding (for lighter rust and smoothing): For lighter rust or after using the grinder, switch to sandpaper. Start with 80 grit sandpaper to remove remaining rust and smooth out the area. Gradually move to finer grits (120, 240, 320, 400, 600 grit) to refine the surface and feather the edges of the repair area into the surrounding paint. Use a sanding block for even pressure and a flat surface. The goal is to remove all visible rust and create a smooth transition between the repair area and the undamaged paint.
Step 3: Rust Converter Application
- Clean the area: Use mineral spirits or degreaser to thoroughly clean the sanded area and remove any dust or residue. Wipe it clean with a rag and let it dry completely.
- Apply rust converter: Apply a thin, even coat of rust converter to the entire sanded area, following the manufacturer’s instructions. The rust converter will chemically react with any remaining rust, converting it into a stable compound and preventing further corrosion. Allow the rust converter to dry completely as per the product instructions. Some rust converters may require multiple coats.
Step 4: Body Filler Application (if needed)
- Mix body filler: If there are imperfections, dents, or uneven areas after rust removal, you’ll need to use body filler. Mix the body filler and hardener according to the manufacturer’s instructions. Work quickly as body filler hardens relatively fast.
- Apply body filler: Apply a thin layer of body filler to the repair area using a plastic spreader. Overfill slightly, as you will sand it down later. Apply in smooth, even strokes, pressing firmly to ensure adhesion. For deeper areas, apply body filler in thin layers, allowing each layer to harden before applying the next.
- Let the body filler harden: Allow the body filler to harden completely. This usually takes around 20-30 minutes, depending on the product and temperature.
Step 5: Sanding Body Filler
- Initial sanding: Once the body filler is hardened, begin sanding it down to shape using 80 grit sandpaper on a sanding block. Sand away the excess filler, gradually shaping it to match the contour of the car wing.
- Refine sanding: Progress through finer grits of sandpaper (120, 240, 320, 400, 600 grit) to smooth the body filler and blend it seamlessly with the surrounding area. Use a sanding block to maintain a flat and even surface. The goal is to create a smooth, invisible repair.
Step 6: Priming
- Clean the area: Clean the sanded area again with mineral spirits or degreaser and wipe it clean with a tack cloth to remove any dust.
- Apply primer: Apply 2-3 thin, even coats of automotive primer to the entire repair area, including a slight overlap onto the surrounding masked area. Allow each coat of primer to dry for the recommended time before applying the next. Primer creates a uniform surface for paint adhesion and helps to hide any minor imperfections.
Step 7: Painting
- Lightly sand primer (optional): After the primer is completely dry, you can lightly sand it with 600 grit sandpaper to remove any imperfections and ensure a smooth paint finish. Clean the area again with a tack cloth.
- Apply base coat paint: Apply 2-3 thin, even coats of automotive base coat paint, matching your car’s color code. Hold the spray can about 8-10 inches from the surface and use smooth, overlapping strokes. Allow each coat to dry properly before applying the next.
- Apply clear coat: After the base coat paint is dry, apply 2-3 thin, even coats of 2K clear coat, following the same spraying technique as with the base coat. Clear coat protects the paint and provides a glossy finish.
Step 8: Finishing and Polishing (optional)
- Remove masking: Carefully remove the masking tape and paper after the clear coat is touch-dry but not fully cured.
- Wet sanding (optional): For a truly professional finish, you can wet sand the clear coat with 2000 grit sandpaper after it is fully cured (usually after 24-48 hours). Wet sanding helps to remove any orange peel texture and imperfections in the clear coat.
- Polishing and buffing (optional): After wet sanding (or if you skipped wet sanding), use rubbing compound and a polishing pad (by hand or with a polishing machine) to polish the clear coat to a high gloss. Buff the area with a clean microfiber cloth to achieve a flawless finish.
Tips for Preventing Future Rust on Car Wings
Once you’ve successfully repaired the rust on your car wing, it’s essential to take steps to prevent it from recurring. Here are some preventative measures:
- Regular washing: Wash your car regularly, especially during winter months or if you live in an area with road salt. Pay attention to the wheel wells and undercarriage, where salt and debris can accumulate.
- Waxing: Apply car wax regularly to protect the paint and create a barrier against moisture and road contaminants.
- Touch-up paint: Promptly repair any scratches or chips in the paint with touch-up paint to prevent rust from starting.
- Rustproofing sprays: Consider applying rustproofing sprays to vulnerable areas, such as wheel wells and undercarriage, for added protection.
- Inspect regularly: Periodically inspect your car’s bodywork, including the wings, for any signs of rust. Catching rust early makes it easier and cheaper to repair.
Conclusion
Repairing rust on your car wing is a manageable DIY project that can save you a significant amount of money and prolong the life of your vehicle. By following this comprehensive guide and taking your time, you can effectively remove rust, restore the appearance of your car wing, and protect it from future corrosion. While it may require some effort and attention to detail, the satisfaction of completing the repair yourself and the money saved make it a worthwhile endeavor for any car owner.
