Discovering rust on your car can be disheartening. If ignored, rust can spread rapidly, turning a vehicle into scrap. While cars have factory rust protection, daily use and minor damages can compromise this defense, leading to corrosion. Professional body shop repairs can be expensive, often costing hundreds, if not thousands, depending on the extent of the damage.
However, don’t despair. If you’re willing to tackle the job yourself, you can effectively stop rust in its tracks and significantly extend the lifespan of your car. The process is straightforward, requiring thoroughness and attention to detail to achieve a successful and lasting repair.
Save Money by DIY Rust Repair
You might be familiar with basic car scratch repair. Rust damage is a more serious issue, and professional rust repair bills can quickly escalate, especially if multiple panels are affected.
By undertaking the rust repair yourself, you can save a considerable amount of money, primarily covering the cost of necessary materials and tools. Investing in a quality rust repair kit is far more economical than paying for professional labor.
Before we dive into the process, it’s crucial to understand the type of rust damage we’re addressing:
Identifying Surface Rust
This guide focuses on surface rust. If your car has severe rust damage, such as rusted-out floors, holes in the bodywork, or compromised structural components like sills or chassis rails, professional intervention and welding are necessary.
Surface rust refers to corrosion that affects the outer panels and hasn’t yet penetrated the metal or compromised the vehicle’s structural integrity. We’re dealing with cosmetic rust spots that, while unsightly, are repairable at home.
Paint Considerations
This guide will take you through the preparation stages up to priming the repaired area. If you’re comfortable painting, you can certainly proceed to apply color and clear coat yourself. Solid colors are generally easier to achieve good results with, while metallic paints require more skill for seamless blending.
If you prefer a professional finish, consider completing the rust repair preparation yourself and then having a body shop handle the painting and blending. Professional spray equipment is designed for an even and flawless finish that aerosol cans often can’t replicate.
Step-by-Step Guide to Fixing Rust Damage
Modern vehicles are significantly more rust-resistant than older models. However, environmental factors like coastal climates or road salt exposure can still lead to rust formation well before mechanical components wear out.
Minor rust on non-structural parts is easily manageable with DIY methods. With careful execution, repairs can be virtually invisible. While classic car restorations often involve cutting out and welding new metal, for everyday vehicles, fiberglass epoxy and body filler offer a simpler and effective solution.
Building upon guides for fixing paint scratches, we now address the progression of scratches into rust. Rust typically begins from minor paint chips caused by gravel or door dings that expose bare metal. Regular car washing and inspections are crucial for early detection.
Promptly applying touch-up paint to chips and scratches can prevent rust from developing, saving significant repair work in the long run. Below are detailed step-by-step instructions to guide you through the rust repair process.
You will need the following tools and materials for this repair:
- Angle grinder and flapper wheels
- Wire brush
- Fibreglass epoxy gel
- Body filler
- Various grades of sandpaper (80, 400, 600, 1000, 2000)
- Sanding block
- Primer and base coat paint
- 2k clear coat paint (aerosol cans are suitable)
- Masking materials (paper and tape)
- Rubbing compound
- Mineral spirits
- Rags
- Tack cloth
Removing and Repairing Car Rust: A Detailed Process
Follow these steps to effectively remove rust and repair the damaged area on your car:
Step 1: Preparation and Cleaning
Begin by thoroughly cleaning the area around the rust spot. Wash the car and use soap and water to remove any dirt, grime, or loose debris. Dry the area completely. This clean surface will ensure proper adhesion of repair materials.
Step 2: Rust Removal
Use an angle grinder with a flapper wheel to remove the rust. Work carefully, focusing on the rusted area and slightly beyond to ensure all corrosion is eliminated. A wire brush can be used for smaller spots or hard-to-reach areas. The goal is to get down to clean, bare metal.
Step 3: Apply Fibreglass Epoxy
Once the rust is removed and you have clean metal, apply fibreglass epoxy gel to the area. This epoxy acts as a sealant and provides a solid base for the body filler. Follow the manufacturer’s instructions for mixing and application. Apply in thin layers and allow it to cure completely.
Step 4: Body Filler Application
After the epoxy has cured, it’s time to apply body filler. Mix the body filler according to the instructions and apply it to the repaired area. Use a plastic spreader to apply thin layers, gradually building up to slightly higher than the surrounding surface. This overfill allows for sanding down to a smooth, level finish.
Step 5: Sanding and Shaping
Begin sanding the body filler with 80-grit sandpaper to roughly shape the repair and remove excess filler. Use a sanding block to ensure a flat and even surface. Gradually move to finer grits of sandpaper – 400, 600, 1000, and finally 2000 – to smooth out the surface and blend it seamlessly with the surrounding paint. Wet sanding with finer grits (1000 and 2000) is recommended for a super smooth finish.
Step 6: Priming
Once the area is sanded smooth and you are satisfied with the shape, clean the area again with tack cloth to remove any sanding dust. Apply several thin coats of automotive primer to the repaired area, allowing each coat to dry according to the primer’s instructions. Primer creates a uniform surface for the paint to adhere to and helps with paint color consistency.
Step 7: Painting (Optional DIY or Professional)
If you are painting yourself, apply the base coat paint in thin, even coats, matching the car’s color code. Allow each coat to dry before applying the next. For metallic paints, follow specific blending techniques for best results. Alternatively, this is the stage where you could take your car to a body shop for professional painting for a guaranteed color match and finish.
Step 8: Clear Coat Application
After the base coat is dry, apply 2k clear coat in several thin, even coats. Clear coat protects the paint and provides a glossy finish. Allow the clear coat to dry completely.
Step 9: Rubbing Compound and Finishing
Once the clear coat is fully cured, use rubbing compound to polish the repaired area and blend it seamlessly with the surrounding paint. This step removes any minor imperfections and enhances the shine. Clean the area with mineral spirits and a clean rag for a final, polished finish.
By following these steps carefully, you can effectively repair rust spots on your car, saving money and preserving your vehicle’s condition. Regular car maintenance and prompt attention to paint damage are key to preventing rust and keeping your car looking its best for years to come.
