How to Remove Surface Rust From a Car

Rust can appear on any vehicle, regardless of age or model, but classic cars are particularly susceptible. Removing surface rust from a car can also be intimidating if you've never done it before. With the right tools, materials, and technique, you can take care of minor rust removal yourself and bring your classic car back to its original glory. Follow the steps below to learn how to remove rust from your car.

How to Remove Surface Rust from Your Car

Before you begin, make sure you pick up the correct paint and primer for your vehicle. If you happen to be working on a classic Mustang, you can pick up some of your primer and paint supplies here.

The method below only works if you're dealing with surface rust. You can easily check whether you are dealing with rust or rot by pressing on the rusted metal and making sure it's not weaker or softer than the surrounding area. There should also be no visible holes in the rust. If there's perforation due to rust, you'll need resort to welding, epoxy, or replacing the panel altogether.

Required Parts and Tools:

Step 1: Scrape Off Loose Paint

Begin by locating the area of surface rust you'd like to tackle. Next, take a paint-scraping tool, and scrape away any loose paint from the rusted area.

Step 2: Lubricate Surface

Spray some WD-40 on a rag and use it to rub down the rusted area. This will clean up the surface for future steps and prevent more rust from forming.

Step 3: Remove Paint Chips and Dust

If you have access to compressed air, use the pressure to push any loose paint chips and dust away from the surface.

Step 4: Remove Surface Oils

Wet down a rag with wax and tar remover to get rid of the oils on the surface of the rusted area. Firmly wipe down the area with the fluid.

Step 5: Tape Off Rusted Area

Use some painter's tape to mark off the rusted area you want to focus on. Put down some newspaper underneath to make sure no paint splashes outside the intended area.

Step 6: Sand Down Rust

Grab some 80 grit sandpaper and firmly sand down the rusted area. Make sure to go over it a few times. Next, move up to some higher grade sandpaper, around 180 grit, and repeat the process.

When you're done with this step, the surface should be nice and smooth. Clean the surface again with wax and tar remover before moving on.

Step 7: Apply Paint Primer

Make sure you're in a well-ventilated area and wear a paint mask for this step. Shake up your paint primer can and coat the rusted area. Make sure to apply coats in long even strokes.

After you get a good coat down, wait for the gloss to dissipate and repeat until you have good coverage of the area.

Step 8: Wet Sand Primer

Wet the primed area with a spray bottle and smooth out any rough patches with some 1500 grit sandpaper. Wipe up any excess moisture with a rag.

Step 9: Apply New Paint

Like with the primer, use long, even strokes to coat the taped-off area with the desired paint color for your car. This will take several coats. Avoid spraying it on too thick to prevent runs in the paint.

Wait for the gloss on the paint to dissipate, then add a second coat. Next, apply a layer of clear coat to add a finished look and protect the painted area.

Step 10: Remove Paint Covers

Once the paint has dried, gently remove the newspaper covers and painter's tape. Make sure you don't damage the surrounding paint

Congratulations, you're all done!

What to Do Once You've Removed Surface Rust

With the rust spots on your car covered up, your exterior should be looking much more presentable. However, if you notice there are any glaring areas of body rot due to rust, you may need to invest in more than a simple paint job. Also, if you have a lot of small dents and dings in your body panels, it might be time for paintless dent repair.

Thankfully we've got you covered with plenty of new body and sheet metal options for your classic car or truck. Shop our wide selection of body and sheet metal to restore your vehicle's exterior to its former glory.