How to Make a Rusted Car Look New

  • 4-10 hours
  • Intermediate
  • 75-200
What You'll Need
Fiberglass repair kit
Body filler
Solvent wipes
Paint (primer and topcoat)
Sanding disk

More often than not, a rusted car is not a vehicle which is particularly admired by a lot of people. Rust starts to develop on a car’s body when the car is exposed to all weather conditions especially if the car has exposed spots. However, restoring a car is not an impossible job and can be done by a resourceful enthusiastic person, but it is certainly a job that requires some skills and a lot of patience. Thus, here are some steps to follow in order to begin restoring a car by removing its rust.

Step 1 – Remove the Loose Rust

Rust is the number one enemy of a car’s body and if a car is rusted all the way through, it can still be repaired providing there is not too much damaged. First you have to remove any loose rust by using a sanding disk in a drill. Ideally, you have to reduce all the rusted spots on your car body to bare metal.

Step 2 – Apply some Fiberglass

Mix some fiberglass paste with the correct amount of hardener and apply the paste behind the holes which were formed by the rust. Press the fiberglass mixture securely in the damaged areas of the car and once ready leave the paste to dry. When the paste has hardened, use the sanding disk again to remove any excess of the paste and to smooth it down.

Step 3 – Apply Some Body Filler

At this point, it is recommended to apply some body filler on the damaged areas. Mix some body filler and hardener and spread it on the repaired areas. Try to cover the damaged parts entirely since rust can start to develop again on the same spots if these are not completely repaired. When the filler has hardened, use a piece of sandpaper to sand it smooth and use a solvent wipe to remove any dust and grease.

Step 4 – Spray the Primer

Before using the primer, make sure to shake the primer can thoroughly. Try to spray the primer evenly on the repaired areas to get an even result. When the primer is dry, wet-sand it and allow it to dry. Then apply another primer coating and wet-sand it again. Repeat the same process again until the primer surface is perfect.

Step 5 – Spray the Top Coat

Once the damaged areas are repaired and coated with the primer, start spraying on the top Coat. Remember that two or three thin coats are often better than a single thick one. When the paint has dried completely, finish the job by polishing the new paint with polishing compound and finally apply some wax.

Now those previously ugly rust-effected areas should look like new. However, try to keep your car in your garage or covered by a canvas cover when outside to protect it from water and the sun, which are the two basic elements which can damage your car body.