In addition to being unsightly, rust on your car can cause several problems. If these are not treated quickly, it can build up and affect your car’s longevity. But fear not, we’re here to help you remove rust from your car effectively.
Understanding Car Rust
What Causes Rust on Cars?
Rust occurs in cars in the same way as it does with any other metal object. It happens through a chemical reaction that takes place when iron, oxygen and water come into contact. Unfortunately, cars are particularly susceptible to rust because they are exposed to many environmental factors like high humidity, acid rain and road salt.
How Rust Can Damage Your Vehicle Over Time
Rust takes a while to damage your car, but once it is severe, it can make your car unsafe to operate. Rust damages your car as it eats away at the car’s body and chassis. This causes failure and structural damage over time. Rust has the potential to eat away as much as 20% of your car.
The most severe stage of rust on a car is known as penetrative ruse. This happens when the rust has permeated the metal, causing irreversible damage. It can create visible holes in your car's bodywork and compromise its structure. This kind of penetrative rust can take years to develop.
Over time, rust can even eat away at your car’s wheel wells, fuel tank housing, engine mounts and other parts.
Tools and Materials Needed for Rust Removal
Where rust is concerned, it’s best to act sooner rather than later to prevent the long-term effects.
Essential Tools for DIY Rust Removal
Here’s a checklist of essential tools for removing rust from your car on your own:
- Wire brushes: These can scrape off the bulk of surface rust. You can get these in various sizes to match your needs.
- Sandpaper: This can help smooth out your car’s surface after the rust has been removed. It also comes in various different grit options. Course grit is good for the initial rust removal, whereas the finer grit is recommended for smoothing out.
- Power sander or angle grinder: This is useful if you are dealing with larger rust spots to make the process faster.
- Drill with rust removal attachments: You can get wire brush wheels or sanding disc attachments for drills which will help access rust in hard-to-reach areas.
Choosing the Right Rust Remover Products
There are many different rust remover products to choose from:
- Rust converters: This helps treat rust that cannot be removed entirely. They chemically transform rust into a stable compound, preventing future corrosion.
- Rust remover gels: These gels dissolve rust and corrosion and also come in liquid form.
- Rust inhibitors: Once the rust has been removed, this creates a protective barrier on the metal, helping to prevent future rust from forming.
- Automotive primer: It’s advisable to prime the metal surface of your car after rust removal to prevent further damage.
Safety Precautions Before Getting Started
It’s important to wear gloves, safety goggles and a dust mask when treating rust so that you are protected from rust particles, chemicals and debris. It’s also advisable to protect areas of the car that you’re not working on, as well as the surrounding area with plastic sheets. In addition, you should
It’s also important to use the right tools for the job as cutting corners could damage your car’s surface. You should also follow product instructions carefully to get the best results and prevent any accidents.
Step-by-Step Guide to Removing Rust from a Car
Identifying Rust Severity
Identifying the severity of your car’s rust will allow you to choose the best course of action. Here is a breakdown of rust severity:
- Surface rust: This rust is usually seen as reddish-brown patches on your car’s surface. It is the lightest form of rust and only affects the top layer of the metal. This can generally be removed with sanding, wire brushing and a rust remover product.
- Scale rust: This rust creates a thicker rust build-up and may start to flake off. This kind of rust may require the use of a rust converter or more extensive grinding. You should treat the area with rust inhibitor products after the removal of this kind of rust.
- Penetrating rust: This kind of rust can eat through your car’s metal and leave holes or weak spots. This requires extensive repair, which usually includes cutting out the rusted sections and replacing them with new metal.
Removing Minor Surface Rust
Follow these steps to remove minor surface rust:
- Clean: Make sure you clean the area thoroughly with soap and water to remove dirt and grime, then dry completely before moving to the next step.
- Wire brush or sandpaper: Use these to scrub the rust from your car’s surface. It’s important to be gentle so that you don’t scratch the surrounding paint.
- Rust remover: Apply this once the rust is loosened. This will neutralize the rust to help prevent future corrosion.
- Clean: You should clean the surface again once the treatment is complete to remove any remaining rust particles.
- Protect: To deter future rusting, it’s advisable to add a rust inhibitor or primer.
Treating Moderate to Severe Rust Damage
For treating moderate to severe rust damage, you should do the following:
- Loose rust: For more severe rust, use a grinder to remove the bulk and the flaky material. This will expose the deeper layers and the underlying metal. You should wear a dust mask and protective equipment while doing this.
- Rust converter: You should then apply a rust converter to chemically transform the remaining rust into a stable compound. You may also want to apply a primer for added protection.
- Fill pits: If rust damage has formed pits or holes, use automotive repair putty or body filler to fill these in. You should apply these in layers, waiting for each layer to try before adding more.
- Sanding: Once the filler is dry, you should sand it smooth with a fine grit sandpaper to create a seamless surface.
Sanding, Priming, and Painting the Affected Area
Once you have treated the rust, you will need to sand, prime and paint the affected area. You should give the entire area final sand with 220-320 grit sandpaper to prepare it for primer and paint. It’s important to clean the area after sanding to remove any dust particles before moving to the next step.
Once the area is clean, you should apply a thin even layer of automotive primer. This will help the paint bond to the metal and will provide an additional layer of protection against rust. Once the primer is dry, apply multiple thin coats of paint to the area. You should wait for each layer of paint to dry before adding another.
When the paint has dried, you can add an additional clear coat of paint to the car’s surface. This will provide added protection and a glossy finish. You should then polish and buff the area so the new paint blends with the existing paint on your car’s surface.
How to Prevent Rust from Returning
Regular Car Maintenance Tips
A number of small actions can significantly decrease your chances of rust returning:
- Car wash: Washing your car regularly will remove dirt and road salts that may contribute to rust formation. It’s advisable to do this at least once a week, paying particular attention to the undercarriage and wheel wells where rust is more likely to occur.
- Drying: It's important to dry your car thoroughly after washing it. Any moisture on your car’s surface can lead to rust formation.
- Inspections: Regularly inspect your car for signs of rust. It’s important to check hard-to-reach areas especially. Early detection can help small areas of rust causing more lasting damage.
- Scratches: Small chips and scratches where your car’s metal is exposed to the elements can lead to rust damage. It’s important to fix these quickly to ensure your car is protected.
Protective Coatings and Rust Inhibitors
There are a number of coatings you can apply to the surface of your car to prevent rust from occurring:
- Rust inhibitors: These sprays prevent moisture from coming into contact with your car’s metal surface and slowing down the oxidation process.
- Ceramic coatings: These offer protection from dirt, UV rays and moisture by creating a hydrophobic layer that prevents water from adhering to the car’s surface. This makes it harder for rust to form.
- Waxing: Waxing creates a smooth surface that repels dirt and water, making it harder for rust to cling onto. It also provides a protective layer against moisture.
Storing Your Car Properly in Different Climates
How you store your car can affect whether or not rust will form. It’s advisable to avoid humid areas as humidity can accelerate the rusting process. If your car will stay in a damp or humid location, you could use a dehumidifier to reduce moisture levels.
It’s advisable to store your car in a dry, covered area like a garage to protect it from rain and snow. You may want to use a car cover if this isn’t an option.
It’s also a good idea to regularly start your car’s engine, particularly if you are storing it for a while. Restarting the engine will circulate fluids and subsequently prevent moisture from building up in the engine, protecting metal parts from rusting in the engine bay.
When to Seek Professional Help for Rust Removal
Signs That DIY Rust Removal Isn’t Enough
DIY rust removal can be effective, but for deeper more penetrative rust, you may need to seek professional help. If the rust has led to holes in your car or caused structural damage to its body, then it has likely compromised the integrity of the metal and it is best to seek professional help. Moreover, rust that causes structural damage is a safety concern, so it is best to speak to a professional in these instances.
It’s also advisable to seek professional help if the rust is located in hard-to-reach areas, as they will likely have the tools and experience to treat these issues correctly. Similarly, if trust keeps returning or you are getting inconsistent results, likely, the rust wasn’t properly treated and it’s best to get it addressed by a professional.
Cost Considerations for Professional Rust Repair
Professional rust repair is more expensive than DIY treatment. If you are seeking professional help, here’s a list of costs to bear in mind:
- Extent: It’s hard to put a cost on damage, but it will always depend on the extent of the damage. Minor repairs will always be cheaper than more extensive ones.
- Labor costs: You will be charged for both the time it takes to diagnose the issue and the time taken to repair it. More time-consuming repairs will be more expensive.
- Parts: If your rust damage requires replacement parts, you will have to cover this cost.
- Insurance: Rust damage may be covered if it’s part of an accident, but this depends on your insurance policy. You should always check if rust damage is covered by your insurance as this may help lower costs.
When it comes to rust, prevention is always better than cure, so it’s advised to always be on the lookout for signs of rust. If you notice any rust spots, attend to these as soon as possible to avoid more serious damage.