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Mac 08-08-2010 03:17 PM

Fixing rust; lots-o-pics
Hey Fellas,
I've had my truck for a couple of months now and thought I'd better get at the rust before winter hits. And here in central Illinois, boy howdy, does it HIT! Year before last we had seven ice storms in two weeks, that was a lot of road salt :SHOCKED:
Anyway, I ordered a paint kit from Set me back about $65 for cleaner, primer, paint, clear coat, and liquid compound. Although after getting into it I'm thinking I might need another kit....more rust than I thought was there, big surprise, lol.
Okay, so for today I grided away the rust, cleaned the areas with Dawn and water, and applied the rust converter. I used Purple Power De-Ruster from Advance Auto. I was going to use POR-15 but after using this on my daughter's car I was pleasantly surprised at how well it did.

This pic is after the grinding. I started with a dremmel but after about 30 seconds I moved to my angle grinder with a wire brush, lol. Man it can be depressing when you start on a tiny dot of rust and it quickly opens up into a 3 or 4 inch area :smiledown: Oh well, at least I got it all.
Driver's Side
Passenger side
After grinding but before converter
Here's a close up after grinding but before converter. It's interesting to note that once you find the edge of the rusted area all you're doing is seeing primer. Kind of a nice way to know you've found it all.
Here's an area that rusted through. I was careful to get up inside the hole with a small wire brush. I'm hoping the converter was pulled inside the seams by way of capillary action.
This is after the converter was applied, about an hour later. It turned a very rich black color. The converter sort of foams up when it hits the rust but just lays on top of the primed/painted areas.
Another "after" image. Some of the converter is still foaming. The rust is now hard and black.
And here's some rust that was hiding under the door weather stripping. I used a very stiff bristle brush, about 3/4" wide to apply the converter. I was very aggressive mashing the liquid into the seams.

Well, that's it for today. It's too humid to paint or apply clear coat. I may have to clean out the woodshop if I want to get this done before winter. The clear coat says it can't be applied in himidity over 50%. Where do they think I live, Arizona?!?! We're looking at heat indexes of 110-115 the next couple of days including 90-100% humidity:doh:

I'll be sure and get more pics when I paint and clear coat. One question though; can I sand and/or buff the converter before I prime? I'm not expecting a body-shop looking paint job but I want it to look as nice as possible.

CajunDodge 08-08-2010 04:35 PM

Wow, that is a good bit of rust there, but not as bad as some I've seen, good you're getting into it now, you're right. I don't see why you couldn't sand the converter, but I'm sure someone with more experience than myself will have some advice for you, but good start, you're definitely making progress. Look forward to seeing it painted! :)

- Cajun

erm 08-08-2010 04:38 PM

Looks like you've done it like it's supposed to be done!

Lotta work though.

Mac 08-08-2010 05:08 PM

Thanks guys. I got to it before it got too hot out. And the angle grinder made quick work of it. A little too quick sometimes, lol.
Yeah, I don't see why I couldn't sand the coverter. After all, it'll have done it's job by the time I get to it, right?

UltraFlame 08-09-2010 07:45 AM

Looks like you are on the fast track to get it all done pretty quick. Bet it will look good as new in no time.

Mac 08-09-2010 10:28 AM

Thanks UltraFlame. I don't know about "good as new" but certainly good enough, lol. The PaintScratch instructions say NOT to sand or buff the final coat of paint before applying the clear coat. I would very much like to blend the new into the old before the clear coat but it doesn't look like that's an option. Oh well.

Mac 08-15-2010 07:30 PM

Update: It's done! Well, sort of. I found a little more rust on the inside bottom of the driver's side door. It's just surface so that's cool.
I have to apologize for not getting in-process pics. One I began I realized that a heavily paint-fogged shop was no place to take my digital camera :Wow1:.
However, things went pretty well considering the heat index of 110. If I had it to do again, (and hopefully I won't, lol), I would have waited for less humid weather. But since I had already grinded the rust down, used the coverter, and watched it starting to rust again, I felt I had no other option.
I used a paint repair kit from It included a wax and grease remover, primer, base coat, clear coat, and liquid rubbing compound. The paint color was an exact match and luckily one can of each was plenty for my needs.
I haven't used the liquid compund yet so it's not as glossy as it will be. I'm supposed to wait three days. I ran into a couple of minor snags like my clamp light failing right when I needed it most and my respirator mask busted an elestic band at a bad moment. I Learned I can hold my breath longer than I thought, lol.
So here's the finished product. All in all, I'm pretty happy.
After using the converter for a second time, I washed the truck real well and used the degreaser. Once it was dry I applied the primer. Once that was dry, I sanded it with 1500 grit wet/dry and washed it again. Then I applied the base coat. I was very careful not to apply too heavy a coat, I didn't want sags and runs. Following the Paintscratch directions, I let the base coat dry and applied the clear coat, again in several thin coats. I let it dry for about an hour then opened the shop to let it air out. After another hour I went ahead and pulled it out of the shop so I could clean it up. My shop is a wood working shop, not a mechanic's shop so I wanted it back ASAP.

I should mention that I was worried about the clear coat fogging because of the high humidity. Even though I had it in my closed shop with the AC on, I could only get the humidity down to about 68%, much higher than the recomended 50%. However, I had no problems with fogging, luckily.

So that's it. I did a lot of masking off which took some time but it was worth the extra effort.

Toms Blue Ram 1500 08-15-2010 07:42 PM

Looks great . Nice job . Rep for ya .

BlueJet 08-15-2010 08:48 PM

Great job!! It has been pretty stinking hot....more props to you for doing this right now!! :158:

City Slicker 08-15-2010 08:52 PM

Nice job, looks great! :smileup:

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