How to Repair Rust

Rust is the oxidation of metal on your vehicle caused by excessive moisture or exposure of bare metal to the elements. All vehicles eventually rust if they are exposed to the elements. Rain, salt (used in the northern United States to de-ice the roads in the winter) and even air can corrode the metal on your vehicle and cause it to rust. If left untreated, the rust will spread and eventually "eat" through the metal, completely destroying the vehicle's body or other components (i.e., the frame). To prevent this from happening, you'll need to know how to repair rust.

Difficulty: ChallengingInstructionsThings You'll Need:

Rust converter and applicator
600; 800; 1,200 grit sandpaper
Bucket of water
Clean shop rags

Step 1
Sand down the rusted area with 600 grit sandpaper to remove any loose rust. The goal is not to try to remove all of the rust, but simply to remove any metal that cannot be saved.
Step 2
Apply a liberal amount of rust converter to the rusted area on your vehicle using the supplied applicator.
Step 3
Allow the rust converter to dry. As it does, the chemicals in the converter will convert the rusted area and turn the affected area black.
Step 4
Wet sand the newly converted rust with the 800 sandpaper until most of the major bumps and pits are smoothed out of the metal. To wet sand, you'll need to soak the sandpaper in a bucket of water and make sure that it is thoroughly wet. This process helps to reduce dust that would normally accumulate on the surface and provides a smoother finish than dry sanding as a result.
Step 5
Wet sand the affected area again using the 1,200 grit sandpaper. Sand until the area is completely smooth to the touch.