Rust Repair DIY 2024 : Learn How to Remove Rust Spots From Your Car at Home

Rust can be a major problem for car owners(especially in humid climates). Rust not only robs your car of its structural integrity but it also devalues it a great deal .Not to mention the hundreds of Dollars that are spent on rust repair. Body shops are usually well aware of the fact that most people are too scared to take on a Rust Repair DIY, so they charge a pretty penny.

Rust most commonly damages surface of items and places that are exposed to the elements (i.e moisture, air and salt).Moisture in the atmosphere cause metals such as iron and steel to develop rust fairly quickly due to oxidation processes. Rust usually leaves brown patches or spots on the metal's surface. 

Read Our Rust Repair DIY step by step guideline so you can easily remove rust from your car at home.

Rust Removal/Repair Step by Step Guideline:

Tools Required :

• Sandpaper Strips (Different Grits)
• Primer (for rust proofing)
• Paint (for covering rust stains.)
• Knife / Paint Removal Tool
• Small Hammer
• Marker
• Masking Tape
• Bondo/Body Filler for dry repair

Step#1: Identify Rust Spots

The first step you need to take for removing rust from your car is actually marking out areas where the rust has corroded you cars body. Make sure you identify all the spots that have already rusted or are currently getting oxidized. The best tool for identification of rust spots would be a small knife or paint removal tool. For areas that are easily accessible try to remove the paint gently with a small knife/paint removal tool. Use a small hammer to tap lightly and identify the weak spots on the metal. Use the marker or tape to mark the areas that need rust removal treatment.

Step#2: Rust Removal

Now that the rusted areas have been identified, its now time to start removing the rust.Use a paper/rag to place beneath the metal. Slowly start removing the rust from the previously identified corrosion spots using a rough grit sand paper. Use a vacuum to remove all the rust-dust that will fall on to the rag in the process. Precaution should be taken with this dust it is harmful to human health and the health of metals in your garage alike.

Step#3: Filling the Rust Holes

After you are done removing all the rust from the corroded areas, you will notice there will be some holes left by the rust in the weaker areas.These holes require filling to prevent further rust issues. Use repair substances such as Body Filler or Bondo. Apply small amounts of Bondo to the affected areas and even out the excess with a squeegee until the filled area becomes indistinguishable. Wait for the prescribed time(varies with brand/product) for the Body Filler/Bondo to dry up.Run your hand over it to check for imperfections in the surface.

If you are faced with large rust holes, some welding might be required. Weld a rectangular plate to close all the gaps and cover a larger zone including the rust spot. The purpose of welding a larger piece of metal on is to cut out the rust agents completely. After welding, grind the excess down with an angle grinder to smooth out the area. 

Step#4: Sanding & Primer Coating

After sealing the holes we need to ensure that the treated area is sanded and primed before painting. Get some fine grit sandpaper and start to wet sand the area to get a smooth surface for primer coating. Once all the imperfections are smoothed out, start coating the treated area with a few coats of primer (2-3 coats are advisable for optimum results).The primer coat will ensure that the treated area is rust proof. Without this step your rust repair job would be incomplete. 

Step#5: Painting the Rust-Proofed Area 

Congratulations! your cars body has successfully been saved from the menace of Rust. Its time to paint. Some fine grit wet sanding would be advisable before spraying on your first coat to get a quality finish. It is important to pick the right paint codes according to your car to match the painted spots with the rest of the car. Paint layers should be sprayed on evenly from a distance of about 6-8 inches. Once all the treated areas have been painted leave the paint to dry preferably in a dust/moisture free environment.