Rust is the corrosion of metal caused by oxygen and water. Rust is not just unpleasant to see, it undermines the structural integrity of whatever it attacks. Cars are particularly prone to rust damage because so much of a car is made from metals that corrode. While prevention is the best cure, if your car has been plagued by small amounts of rust you can take care of this problem with the right tools and some time.
Remove parts of the car that are blocking your access to the rust rot. If you can’t access it entirely, move as much as possible.
Check both sides of rotted part to see if the rust has reached the front and back. You need to clean each rusted side separately.
Hold the die grinder lightly against the rust on the front of the part. Use the edges of the stripping disc to carefully remove layers of the rust until it is cleared away.
Clean the rust away from the other side of the part if it has rusted through. Remove the rust on that side in the same manner.
Remove any rust that is caught in small dips in the parts with a sandblaster. Wear protective goggles and a facemask when sandblasting to keep the rust and sand out of your eyes, nose and mouth.
Wipe down the rust free part with a damp cloth to remove any dust and particles. Wait for the part to dry and apply the rust inhibitor and pre-primer to prevent any further rust.
Let the pre-primer dry and inspect the parts for inconsistencies on the surface. Fill the depressions with plastic filler and smooth it down with a squeegee.
Sand the plastic filler with sand paper until it is smooth and flush with the rest of part. You may need to sand more than once before you can achieve the smoothness necessary for the part.
