How to Repair Rust on a Car

Rust repair isn’t hard, but it is time-consuming (mostly waiting for primer and paint to dry between steps). Plan to spend about $100 on supplies like sandpaper, primer, masking tape and poly sheeting, a tack rag, polishing compound and touch-up paint and clear coat. Choose a calm, overcast day and block out the full day to fix the most common rust spots on the hood and doors.

Go Shopping for Supplies

• First, find the car manufacturer’s paint code.
  • Note: The paint code can be in a variety of places on the body, in the engine compartment or trunk, or other places. Use either of these online resources to find instructions on how to locate your paint code: automotivetouchup.com or duplicolor.com.
• Buy automotive touch-up paint in pints and quarts to use in a spray gun, in aerosol cans, or in roller ball applicators.
  • Pro tip: Even if you know how to use a spray gun, mixing automotive paint with a reducer to match the temperature and humidity conditions can be mighty tricky. We don’t recommend it. Instead, buy aerosol cans for larger repairs and rollerball applicators to fix scratches.
  • Note: Most late-model vehicles were painted with base coat/clear coat paint. The base coat contains just the pigment and binding resins-the clear coat is just the gloss.
• Buy equal amounts of both base coat and clear coat.
• You’ll also need an epoxy self-etching primer to bite into the bare metal and a lacquer primer to hold the paint.
• Buy 40-, 600- and 1,000-grit sandpaper, a sanding block, grease and wax remover, poly sheeting, painter’s tape, a tack rag and a microfiber cloth.

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