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How to Repair Minor Auto Body Surface Rust

Nov 13th, 2009 by skypilot69
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Very simple to do and will make your vehicle look good as well as increase it's value!

What we are going to learn to do here by following my few simple steps is to get rid of those unsightly surface rust spots and get your car back into showroom condition. The process is very simple and anyone can do this. Not only do you get your car to look good once again but you also increase it's value.

 Things you will need: 

  • an electric grinder
  • a small hammer
  • a bondo repair kit
  • a spray can of primer
  • a package of assorted auto body sanpaper (200-600 grit)also some 60 grit
  • a spray can of touch -up paint (to match existing color)
  • a spray can of clearcoat
  • and some polishing compound 2or3 tack rags
  • Step 1

    First thing we want to do is to tape off the area around the bad spot. This is to protect the area around the bad spot while we work on it. Give yourself approximately 5" of area around the bad spot.

  • Step 2

    Now what we want to do is to tap the bad spot with your hammer to break away any loose rust. Then we take the grinder and grind down the bad area until it leaves bare metal in the damaged area. The next thing would be to slightly recess the bad spot by tapping it with the hammer. This allows you to use the filler without raising the bad area.

  • Step 3

    Next we will mix a little bondo according to the directions in the kit. With the squeegee provided in the kit apply the bondo in an even manner over the bad area.Allow this to dry, it will dry in a matter of minutes.

  • Step 4

    Now you are ready to sand down the area with a piece of 60 grit sandpaper until most of the bondo you applied has been sanded off. Then you will take a piece of 220 grit paper and go over the area to remove and scratches from the 60 grit paper.

  • Step 5

    Once you have the area smooth and flush the next step would be to prime the area with a couple coats of primer(very light coats,you will have to spray it 2 or 3 times to get complete coverage.Allow it to dry between coats.

  • Step 6

    When you have the area all primed and are satisfied with the results take a piece of 400 grit paper and sand the area to a smooth finish.You will want to sand a couple of inches bigger than the worked on area to feather it in. Once this is done you are ready to apply the color.

  • Step 7

    Before applying the color coat take a tack rag and wipe the area clean. This will all dust particles to insure a good finish. Apply color like you did with the primer, very light coats allowing it to dry between coats. It could take 2 or 3 coats to get complete coverage. Once you have complete coverage we will be ready to light sand the area with 600 grit paper to remove any roughness.

    Step 8

    • The next and final step would be to apply the clearcoat in the same way you applied the color including sanding it with 600. Let it sit for a few hours to complete the curing process. Now you are ready to rub it out with the polishing compound.But before we do that let's remove the tape and rub out the whole area. Now wax it and you have completed your repair, looks good doesn't it?
    • skypilot69

    Written by skypilot69

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