How to fix small rust spots on car

While rust-proofing your vehicle is a great way to prevent rust spots from developing throughout the years, this type of preventative maintenance task isn't an option for many drivers, especially if there are already rust spots on their car.

Rust on your vehicle is a cause for concern. But the good news is that you can fix rust spots at home with a couple of tools you can purchase at your local automotive store. To learn how to remove rust the right way, stick around and follow our step-by-step guide below.

How do rust spots form

First things first, how exactly do rust spots develop? Rust develops when oxygen, water, and iron come into contact with each other. And because the majority of your vehicle is made from sheet metal, rust can appear almost anywhere on it. In fact, not only can rust appear on the surface of your vehicle, but it can also develop in concealed areas that are difficult to notice.

Repairing minor rust spots on a car

Generally speaking, if you discover surface rust or scale rust on your car, performing a do-it-yourself repair is possible. If you're up for the challenge, here's what you need to do to fix a small rust spot on your car:

1. Gather your supplies and paint code

Before you start removing rust, you need to gather your supplies and the paint code for your car to ensure an exact match. Beyond the paint code to your automotive paint, here are the supplies you will need to purchase from an auto parts store if you do not already have them:

• A plastic sheet
• Painter's tape or masking tape
• Grit sandpaper
• Car wax remover
• Grease remover
• A microfiber cloth or lint-free cloth
• Dust mask
• Safety goggles
• Body filler (epoxy primer)
• Spray gun or spray cans

2. Prep and clean the area

As you will be using grit sandpaper to remove the pain and rust, we recommend performing the rust repair in a well-ventilated space. Make sure to wear your protective eye gear and mask to avoid breathing in the dust. Next, using your painter's tape, take your plastic sheet and tape off the paint area where the rust has developed.

Now, you can go ahead and use a bit of car wash soap to clean the area in question. This will remove any dirt and other debris that may be stuck to the outer paint.

3. Sand the rusty area

Once the area is clean, take your 60-grit sandpaper and begin your rust repair by sanding through the automotive clear coat and automotive paint until you've reached the metal. Next, switch to 120-grit sandpaper and sand down the surrounding paint to make the surface smooth. You'll then want to use 220 grit sandpaper to ensure the entire area and its edges are feathered. Finish sanding the entire area with 400-grit sandpaper to ensure all of the rust has been removed.

4. Clean the area again

If the rust has created pitted metal in the body of your vehicle, you can go ahead and apply a small amount of body filler into the holes. Once the body filler is dry, use your microfiber cloth to clean the area with detergent to remove any grease. After soap, use a clean microfiber cloth to ensure the area is completely dry.

5. Apply automotive primer and automotive paint

Now, it's time to use a spray primer on the entire repair area. We recommend using a self-etching primer first, as it will create a tight seal. Once the first layer is down, you can go ahead and use the etch primer again for another two to three coats. Afterwards, wait for the allotted time listed on the spray can to ensure that the primer is dry and the area is sealed.

With the primer now dry, you'll need to go ahead and lightly sand the primer down to ensure the surface is smooth. Start with 600-grit sandpaper and then switch to 100-grit sandpaper to smooth out the area and blend the edges. You can then go ahead and use your cloth to wash and clean the dust off.

Next, start by applying your coloured base coat using a spray gun. The goal is to apply thin coats to ensure the final paint job doesn't look bulky. We recommend standing 12 inches away from the car itself. Once the base coat is dry, you can put another thin layer over the top. Generally speaking, you should aim to have two to three layers of new paint.

Finally, you can go ahead and paint several thin coats of clear coat over your original paint colour. Allow the clear coat to dry for 48 hours before proceeding.

6. Buff and wax the affected area

Once you've waited for the paint job to dry, you can buff out the area with your microfiber cloth. To ensure that the area is cured, we recommend waiting at least 30 days before adding a wax coat to the area.

Different types of vehicle rust

As we just said, the majority of your vehicle is made of sheet metal, making it possible for rust to develop in numerous areas. Here's a closer look at the different types of rust you may be dealing with:

Surface rust

Surface rust occurs on the outer part of your vehicle, typically on the clear coat. When there are chips in the clear coat, the paint underneath can develop surface rust over time as your car comes in contact with different weather elements. Luckily, because the surface rust is only as deep as the clear coat rather than the bare metal of your body panel, your rust repair will be fairly straightforward to perform.

Scale rust

The next type of rust that can develop on your car is scale rust. Scale rust occurs when you leave surface rust to develop beyond the clear coat of your vehicle. As the corrosion process continues, the scale rust will begin to develop into the automotive paint and the bare metal of your body panel. If left alone, the scale rust will cause further damage to your vehicle.

Penetrating rust

Penetrating rust is the final type of rust spot you may discover on your car. Penetrating rust occurs when the rust itself has corroded through the metal of your vehicle, creating holes and other damages. Because this type of rust damage is more extensive, rust removal processes won't be successful, meaning you will likely need to replace portions of your vehicle panels altogether. For this type of repair, it's recommended that you work with a reputable mechanic to ensure the body panels are removed and reinstalled correctly.

Rust repair techniques by severity

Rust severities can range from surface-level rust to rust that causes structural damage to your vehicle. Here are some different techniques you can use, depending on how much damage your vehicle has sustained:

Light surface rust

Here are the steps to fix light surface rust. First, gather your materials. Then, follow each step carefully for the best results:

1. Start by sanding the rusted area on your vehicle with a light, 80-grit sandpaper.
2. Next, rub the area with an alcohol wipe or grease remover to ensure the area is clean and free of debris.
3. Apply a rust converter to neutralize the rust particles on your car and serve as a protective rust inhibitor.
4. Once dried, spray a self-etching primer on the treated area. This will prevent oxidation and ensure a smooth finish once dried.
5. Sand the area once again using 400 grit sandpaper.
6. You can then go ahead and paint over the sanded area with some touch-up paint, followed by a clear coat.

Moderate rust (pitting and small holes)

Moderate rust includes spots and small holes. It's not too severe, but it needs attention. If left untreated, it can spread and cause more damage. Follow the following steps carefully for the best results:

1. Use a sanding block or disc to remove the rust, ensuring the metal is bare.
2. If there is still a small pit remaining, you can use a rust converter on the area. Ensure it has time to dry and cure.
3. To fill in the metal imperfection, use a body filler. You can purchase these at your local auto store.
4. Once dried, use 180-grit sandpaper and follow along the metal panel to smooth out the area.
5. Next, apply a self-etching primer and paint to follow.

Severe rust spots (larger holes or structural damage)

Big rust spots, such as large holes or damage that affects the structure, are severe. Follow each step carefully for the best results:

1. Using a cutting wheel or shears, cut out the rusted sections of your car. You'll want to ensure that you cut out not just the rusted paint but a small area around it as well to ensure all the rust is removed.
2. Next, you'll need to weld a replacement panel to the surrounding area of your vehicle. Ensure a tight and flush fit.
3. Using a flap disc, you'll then need to grind down the welds and apply a body filler or epoxy primer if required. The goal is to ensure the new panel is as flush as possible.
4. Now, you can go ahead and sand down the area. Start with an 80-grit, then move to a 320-grit.
5. Finally, apply a primer and paint, followed by a clear coat for a smooth finish.

Paint blending

Blending your paint job can be difficult, especially if you've never fixed rust on your vehicle before. To ensure you get a smooth finish, consider the following:

• Colour match: For an accurate paint match, find your vehicle's paint code. Make sure to test a small area before using the paint on your car.
• Feather the edges: Use 800-grit sandpaper to feather the edges around the repaired area. This will ensure the paint blends seamlessly.
• Blend into the surrounding paint: Use a spray paint gun to light mist into the surrounding area.

It's important to note that if you do not have the proper tools available and do not feel comfortable removing the rust on your vehicle yourself, we recommend booking an appointment with a reputable body shop in your area. Having a professional mechanic and car detailer perform the rust repair can give you peace of mind, knowing that the job is being performed correctly.

Alternative methods for removing rust

Alternative rest removal methods are available if you don't feel comfortable using the items we've listed above. A bonus is you can typically find these products in your pantry:

• White vinegar: Acid found in vinegar can dissolve rust over time. Soak a clean cloth in vinegar and apply it to your car for a couple of hours. Then, use a scrub brush to remove the rust. You can follow this with paint and a clear coat.
• Baking soda: For light rust, make a paste using baking soda and water. Apply the paste to the rusted area. Let it sit for an hour or two before scrubbing the area with a brush. Wash away with some water.
• Lemon juice and salt: The acid in lemon juice can break down rust, while the salt enhances this chemical reaction. Apply the lemon and salt to the area. Allow it to sit before scrubbing off with a brush. Clean the area with some water to finish.
• WD-40: Apply a generous amount of WD-40 to the area and leave it to soak into the rust for at least 10 minutes. Once time has passed, scrub the WD-40 with a wire brush to ensure the flakes of rust are completely removed.

Generally speaking, for surface rust or smaller areas on your vehicle, using a chemical or home remedy should do the trick. In contrast, sanding and touch-up paint should be used when the rust is deep, pitted, or you notice blistered paint.

Regardless of which method you use, remember that wearing protective gear is imperative. Wear gloves and protective goggles to prevent eye irritation. Finally, if you're using chemicals, make sure the area you're working in is a well-ventilated space.

How to prevent rust and protect your vehicle from unexpected hazards

Your vehicle is an investment, which is why you must protect your interests and finances while on and off the road. In Canada, all drivers on the road must have proof of valid car insurance. The minimum coverage options and policies will, however, vary between provinces and territories. Beyond these mandatory policies, there are also add-on coverages that you can purchase to further supplement your standard insurance. Here's a closer look at the different types of auto insurance in Canada:

Third-party liability insurance

Third-party liability insurance is a mandatory insurance policy for all drivers. It protects policyholders in the event they cause bodily harm or property damage to a third party while operating their motor vehicle. Should a lawsuit be filed against them, this insurance policy will cover the cost of repairs, replacements, medical bills, funeral costs, legal fees, and any settlements that are reached up to their coverage limits.

Accident benefits coverage

Accident benefits coverage is also mandatory for all motorists in Canada, except those living in Newfoundland and Labrador. In the event you are involved in a collision where you, your passengers, or pedestrians are injured, accident benefits coverage will cover the cost of medical and rehabilitation costs, lost wages, and other fees, regardless of who is at fault for the accident.

Uninsured automobile insurance

Uninsured automobile insurance is the final insurance policy that is mandatory for all motorists in Canada. This insurance will cover you if you are involved in a car accident with another at-fault driver who is either uninsured or underinsured, guaranteeing that you are fairly compensated for your losses. Uninsured car insurance also protects policyholders if they are involved in a crash with a hit-and-run driver.

Comprehensive insurance

Comprehensive car coverage is an optional insurance policy but is nonetheless highly recommended for drivers. If your vehicle is damaged in a non-collision event, your comprehensive insurance will cover the costs associated with repairing or replacing your car. Common covered perils included in this policy include theft, vandalism, severe weather, falling objects, and fire damage.

Note that before your insurance provider will pay for your repairs, you will need to pay a deductible, which is an out-of-pocket amount you agreed upon at the time you purchased your insurance coverage.

Collision insurance

Collision car coverage is another type of optional insurance that Canadian motorists should consider. Similar to comprehensive, this insurance policy will cover the cost of vehicle repairs or replacements if your vehicle is damaged. However, this insurance will only kick in if you are involved in a car accident where you are found at fault. Again, before you can file a claim for damages, you will need to pay a deductible amount to your insurance provider.

Accident forgiveness insurance

Accident forgiveness is additional coverage that can be added to your car insurance policy as an endorsement to protect your driving record and to help prevent your insurance premium from increasing if you have an at-fault accident claim.

Note: coverage varies by province.

Full coverage

While there is no car insurance policy called "full coverage", it technically means that a person has purchased additional policy options beyond mandatory insurance, such as comprehensive collision, waiver of depreciation, rental car coverage, and accident forgiveness, to supplement their plan. So, whether you damage your car by hitting a curb or your car is damaged by a covered peril that leads to rust development on your car, you can claim some vehicle damages with your insurance. Otherwise, you'd be responsible for paying out of your own pocket.

Additional rust prevention tips

Preventing rust from developing is far easier than repairing it, which is why regular car maintenance is essential. Here's what you need to consider:

• Frequent car washes: Dirt, grime, and road salt can do a number on your vehicle and accelerate rust development on your exterior. Make sure you're washing your car at least once every two to three weeks, especially in the winter.
• Car waxing: Have a professional apply a car wax every three to four months, or apply on yourself. Wax creates a protective barrier that can prevent moisture, salt, and other contaminants from developing into rust.
• Rustproofing: Apply a rust-proof treatment to the undercarriage of your vehicle and other exposed metal parts to prevent rust from developing.

Environmental factors that create rust

Rust is caused by several environmental factors. Exposure to these factors create the perfect conditions for rust to develop. Here's what you need to know:

• Exposure to moisture: Rain, snow, and high humidity levels are the perfect conditions for which rust can develop. If possible, consider parking your vehicle in a dry, well-ventilated area and dry your car off when possible.
• Winter temperatures and road salt: With unavoidable Canadian winters, road salt is common. When temperatures drop, and road salt becomes prevalent, ensure you rinse the undercarriage of your car as often as possible.

Contact BrokerLink for affordable auto coverage

At BrokerLink, we help Canadians find affordable car insurance. With access to multiple auto insurance policies from top insurance companies, our experienced brokers can help you customize an insurance plan that fits your unique driving habits and budget. We're also an information hub! Learn more about insurance topics ranging from safe driving tips to the benefits of extended warranty to ensure you remain up-to-date on all things related to your coverage needs.

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