8 Simple Steps How to Repair Auto Body Rust and Restore Your Car's Shine

NHTSA says that rust damage costs almost $6 billion every year in car repairs throughout the U.S., and most are the result of ignored small rust areas that spread gradually.

Rust doesn't simply detract from a car's looks-it also undermines the structural integrity of the vehicle, resulting in expensive repairs if left unaddressed. The silver lining? You can stop significant damage in its tracks with some simple do-it-yourself techniques.

This manual will take you through simple steps to fix auto body rust, saving you from costly shop charges while making your vehicle shine once more. We begin with tools, techniques, and tricks for long-term results.

1. Collect Your Tools and Materials

Before beginning, ensure that you possess all that you require. The correct materials and tools will make the job easy and provide professional-grade outcomes.

Essentials:

• Sandpaper in various grits (60, 120, 400, 600, and 1000)

• Rust converter

• Auto body filler

• Self-etching primer and filler primer

• Automotive touch-up paint and clear coat

• Painter's tape, poly sheeting, and a tack cloth

• Microfiber cloths and grease remover

• The use of quality materials is most important. For example, using a good rust converter will effectively neutralize the rust, so it does not spread later.

2. Prepare the Work Area

An uncluttered, clean work area is essential for repair to proceed smoothly. Work in well-ventilated conditions to prevent inhaling paint and primer fumes.

Steps:

• Take care to wash the soiled area with soap to remove grease and dirt.

• Dry completely with a lint-free microfiber cloth.

• Mask surrounding areas with tape and poly sheeting to keep them safe from overspray or accidental sanding.

• A clean surface not only makes the process simpler but also enables the materials to stick appropriately.

3. Evaluate and Strip Rust

Examine the damaged section in detail to determine the extent of repair needed. Surface rust can generally be sanded, but deeper damage may require extra work.

How to Strip Rust:

• Use 60-grit sandpaper to sand away loose rust and paint.

• Change to higher grits, such as 120 and 400, to polish the edges of the rusted section.

• For heavy rust, use a rust converter to kill corrosion and provide a stable base for repair.

• Pro Tip: If rust is severe or metal is consumed, use auto body filler after sanding.

4. Use a Rust Converter

Rust converters convert rust chemically into a protective coating. They also treat the surface to enable painting, removing the possibility of future corrosion.

Steps:

• Apply thinly with a foam brush or microfiber cloth.

• Allow it to dry according to the product guidelines.

This step not only prevents active rust but also provides an excellent bond for applying paint.

5. Repair Dents or Holes

For those regions where rust has also taken a toll, it is important to fill the gaps to level the surface.

Auto Body Filler Application Steps:

• Combine the filler and hardener as directed on the package.

• Work with the mixture using a plastic putty knife to spread the mixture into the compromised area.

• Allow it to cure for approximately 20 minutes, then sand it with 120-grit sandpaper.

• Sanding completes the process of making the area look like it's part of the surrounding metal.

6. Prime and Paint

Priming and painting are essential to preserve the fixed part and blend it into the rest of the vehicle.

Steps to Apply Primer:

• Spray a self-etching primer over bare metal and filler.

• Follow with filler primer to fill in imperfections.

• Let each coat dry before sanding lightly with 600-grit sandpaper.

Painting Tips:

• Touch up paint in thin, even layers.

• Overlap edges to blend in with existing paint.

• Always shake the spray can thoroughly to avoid uneven application.

7. Seal with Clear Coat

The clear coat provides a glossy finish and guards the paint job from weather and wear.

How to Apply:

•  Spray several thin coats, with sufficient drying time between each.

• Merge the clear coat with the surrounding paint for a perfect finish.

• Avoid over-spraying to produce the best results, as clear coat can run if applied too thickly.

8. Inspect and Maintain

Once the paint is dry, check the area in good light for any faults.

Maintenance Tips:

• Don't wash or wax the area for at least 30 days to allow the paint to fully harden.

• Clean your car and wax it regularly to avoid rust from redeveloping.

• Taking all these precautions guarantees long-term results and keeps your car looking