Before we introduce car rust repair let’s see why is that highly recommended!

Car rust is an undesirable and unfortunate reality that every car owner has to face. This problem not only detracts from the appearance of Your car, but can also lead You to expensive repairs.  You should be aware that after a few years, oxygen, and water will convert any iron to rust causing it to disintegrate. You can instantly recognize it by formation of bubbles. If it progresses any further, the metal will flake away and leave a hole. Greater problem is that rusty surface doesn’t provide enough protection.

Don’t allow Yourself to be sloppy when it comes to car rust maintenance. It will eventually lower Your cars value. We suppose You would never buy a rusty car because it is also an unsafe car. But, unfortunately repair at autoshop can be quite expensive.  So there are quite enough reasons why You should learn  to do car rust repair Yourself.

For  car rust repair You will need:

  • – 40, 80, 320, 400 grit sand paper for smoothing the filler 
  • – 600 grit for primer smothering
  • – Alcohol for cleaning
  • – Rust reformer and rubberized undercoating for the back side if needed
  • – Hammer or screw driver
  • – Adhesive body patch if there are holes
  • – Flat board and scoop (spreader)
  • – Fiberglass infused body filler
  • – Gold body filer
  • – Primer
  • – Original color base coat spray paint
  • – Original color clear coat spray paint
  • – 1500, 2000, 3000, 5000 grit sandpaper for finished touch
  • – Polish for shine
  • – Microfiber towels and protective glasses

Let’s begin with car rust repair!

1. Remove the rust

Before sanding the surface, use alcohol to clean the surface and then begin to sand. Do it until You can see shiny metal. It is important to be patient and remove all critical spots, because if You miss any it will spread again. Send the surface one centimeter away from the rusted area. When You are done check if the rust contaminated the back of the metal and sand it with same grit in the same way. Since You won’t paint the inner part of it, use alcohol to clean it and spray it with rust reformer and rubberized undercoating (wait couple minutes until rust reformer is dry before applying undercoating). Now, You are ready to do the filling part.

Remove the rust
Remove the rust

2. Prepare for the filer

Take the hammer and hammer the surface inwards. For smaller spots You can use screw driver to do it. This is very important because filler will add extra layers to it, and You don’t want it to be uneven. If there are holes or the rust contaminated the edges take an adhesive body patch to fill the holes and reshape the edges. Just put it behind the metal, restore its shape just like it was before. After You’re done, use alcohol to clean from dust.

Adhesive body patch

3. The fiberglass infused body filler  

The fiber glass filer will strengthen the week metal. In order to use it You have to mix it with hardener. Use any metal or hard flat surface and a scoop (a body filler spreader). You can purchase both these items online for less than 8$. Place the filler in circular shape on the board thickness of half inch. Add hardener along the diameter of the circle and You will have correct ratio. Don’t mix it in circular moves because this will only add air to the filer. Take it with the scoop and spread it on the board, repeat it until You have even color. This shouldn’t take more than a minute, because it will start to dry.  Apply it on the metal surface by pressing it. After 15 – 20 minutes, take the 40 grit sandpaper and start sanding the surface. Make sure You follow the lines of the car to keep its original shape.

body filler
Correct ratio for hardener and body filler
body filler
Mixing hardener with body filler
body filler
Applying the body filler

4. Gold filer

Repeat the same mixing process like before for gold filer. After You’re done put it in thin layer on the surface until it’s thicker than the body since You will have to sand it again. After 20 minutes it’s ready for sanding. Use the same 80 grit paper to get the correct shape. Take 180 grit sandpaper to blend the filler with body panel. Before proceeding to 320 grit sanding, it is good to apply thin layer of glazing and spotty putty which will fill all tiny holes You can’t see. After 15 minutes You can sand it with 320 grit paper and then with 400 grit.

gold filler
Sanding surface before applying primer

5. Primer

Clean the dust off and protect the body panel with curved paper (You can see in the video how to do that). Apply 3 coats of primer.


6. Spray paint – base coat and clear coat

Use the same spray paint as the original color. Before painting take 600 grit sandpaper and soften the transition between the body panel and primer. Clean it with alcohol when done. Protect it in the same way as before.  Add 3 layers of base coats (wait it to be dry in between).

Sanding the primer

7. Spray paint – clear coat

After the base coat is dry, do the same with clear coat. In order to prevent the orange peal put the clear coat in hot water for 10 minutes.

spray paint
Clear coat spray paint

8. Finish

After least 24 hour You can do the finishing touch. Use soapy water and 1500, 2000, 3000 and 5000 grit sandpaper. Make sure You apply lot of soapy water.  Dry it every time before proceeding to different sandpaper. After You’re done with sanding, let it dry completely. For final step use polish to bring the shine back.


Watch the video of amazing ChrisFix in order to learn all details of rust repair, as we highly recommend it if you are a beginner or want to improve!

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Your automotivefixing team