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Depending on the severity of the rust, a decision must be made whether to repair the rust spot, or replace the whole body panel. New panels are not nearly as expensive as most people think, and it may be quicker to replace the panel than to repair a large area of rust. For that reason, this article will be limited to the repair of minor rust spots.
1. Always wear proper eye protection and use care practice good safety procedures.
2. If a scratch or blemish has caused the body metal to rust, remove all rust from the bottom of the blemish with a pocket knife. Then apply rust inhibiting paint to prevent rust from forming again later.
3. Coat the affected area with glaze-type filler, using a nylon or rubber applicator. If need be, the filler can be mixed with thinner to make a thin paste. This is easier to apply when the scratch or blemish is small or thin.
4. Before the filler in the blemish sets and hardens, using a smooth piece of cloth, (cotton or a material that won't leave a residue in the glaze filler), wrap the cloth around your finger and dip it in the thinner. Then quickly wipe it along the filled surface of the blemish. This ensures that the surface of the filler will be slightly hollow and accept paint more easily.
5. Once the filler has completely hardened, any remaining irregularities in the surface can be removed with fine grit sandpaper, about 180 grit or finer, progressing to finishing with 600 grit wet- or- dry paper. Always wrap the sandpaper around a flat rubber or wooden sanding block, ensuring that the surface of the dried filler is completely flat and coming in contact with the paper. During the sanding, periodically rinse the surface of the wet- or- dry sandpaper with water. This will give a very smooth final finish.
6. At this point, rinse the surface with water to remove any sanding dust. Dry completely and spray the entire area with a light coat of primer. This will reveal any imperfections that may remain in the surface. Repair them with a thin coat of primer, and repeat the sand, prime, and fill procedure until the imperfections are gone.
7. The repaired area is now ready for painting.
