How to Remove Rust from a Car Without Sanding

Rust is a car owner’s worst nightmare, and it can cause severe structural deterioration to a vehicle when left alone. While sanding is a common fix for rust removal, it is a time-consuming process that can damage the metal when done incorrectly or carelessly. Fortunately, there are alternative solutions to get your car back to looking brand new.

How do you remove rust from a car without sanding? If you are looking for an effortless way to remove rust from your vehicle, look no further than a chemical remover or converter. Removers and converters can rid your car of rust without grinders, sanders, or power tools of any kind.

Save yourself an expensive trip to an auto shop by turning rust removal into a DIY project. Before you get started, here is everything you need to know about using chemical removers and converters to make your vehicle rust-free.

What is Rust?

The formation of rust is a chemical reaction caused when iron is oxidized in the presence of water and electrolytes. Rust is usually an orange or reddish-brown discoloration and can take on different visual appearances depending on the type of rust. There are three types of rust you should be on the look-out for.

  • Surface Rust: Surface rust appears in paint nicks, cracks, and scratches and is easy to contain if treated quickly. Touch up minor nicks and scratches as you notice them, and surface rust will be kept well under control.
  • Scale Rust: Once corrosion pits the metal, it is identified as scale rust; this happens most often in areas where dirty or salty water is trapped within the body of the vehicle, speeding up the corrosion process. Eventually, scale rust works through the surface and damages the structural integrity of the metal.
  • Penetrating Rust: Penetrating rust is the most advanced stage of rusting that results in holes in the metal. Parts affected by penetrating rust are no longer salvageable and will have to be replaced. Touch up surface rust to prevent penetrating rust from ever happening.

Removing Rust from a Car Without Sanding

Chemical removers, which often contain oxalic, phosphoric, or hydrochloric acid, work by directly dissolving rust, while rust converters convert iron oxide (rust) into a protective chemical barrier. Converters and removers come in three forms:

  • Liquid: Most removers and converters are liquids. While different brands have varying viscosities, they can typically be painted or sprayed on without much difficulty. For challenging rust jobs, parts can also be submerged in a tub.
  • Gel: Only converters come in gel form and are too thick to be used in sprayers. The plus side is that their thickness allows them to adhere to vertical surfaces without dripping off. Paint or roll the gel on and allow it to dry for the best results.
  • Spray: If you desire a faster application process, try searching for a remover that comes as an aerosol spray. Due to their smaller quantity, these are best used for localized rust removal.

Most rust treatments can be applied by brushing, rolling, or spraying it onto the affected surface. Make sure to follow brand-specific instructions when using chemical removers and converters. While some products only require a couple of hours to cure before you can sand or paint over them, some removal products suggest leaving them on for a day or longer.

Once the chemical has sat for the specified time, remove it with water. Following, apply a rust inhibitor to help prevent future rusting.

Pros and Cons of Chemical Rust Removal

Pros:

  • Quicker than alternative methods
  • Requires less physical labor
  • Less likely to damage the metal
  • May have a built-in primer
  • Easy to do at home and by yourself

Cons:

  • Leave pockmarks or discoloration and are typically only used on surfaces that will be painted over
  • Large rust jobs might require a lot of substance and end up quite pricey
  • Corrosive chemicals can be dangerous

Other Methods for Removing Rust

While chemical removers and converters are simple and effective, they do contain potentially harmful toxins that some people may not want to handle. Here are a couple of safer methods for removing rust from a car:

  • Citric acid: Buy the powder from your local store or off Amazon, add hot water, and apply the mixture to the affected area.
  • Steel wool: Steel wool can be used to scrape off the rust, though it requires more physical effort.

Steps for Safely Removing Rust from a Vehicle

Ready to remove that worrisome rust from your car? Below are a few steps you can take to remove it from your vehicle effectively:

Set up your workspace

Depending on how much rust you are working on, you will need to plan out your workspace accordingly. The outdoors provides the convenience of open space; however, it also exposes your project to the elements. Thus, an indoor garage is preferred. While working indoors, make sure that the area is well-ventilated. You do not want to breathe in rust particles or possible chemical toxins.

If you do not have the luxury of a spacious garage, make sure you check the weather report for clear skies—you would not want your car to leave with more rust than it started with. While working outdoors, make sure that your vehicle remains dry, clean, and out of the sunlight. Keep in mind that the whole process might take up to a couple of days if you are also planning on applying paint to the surface.

Don your protective gear

Even if you are only working with a small area, do not give in to laziness. When working with any chemicals, you must take the appropriate safety measures. At the very least, wear protective gloves, safety goggles, and clothes that are not loose but still provide full coverage.

Especially if you are working in an enclosed space, consider a surgical mask or respirator. Many chemical products for rust removal can be harmful to your skin, and direct contact should be avoided.

Prep the area

Before you get started with removing the rust itself, you will need to prep the area that you are working on. Isolate the rusted section of the car the same way you would for a paint job by covering the unblemished parts with masking paper to protect them from rust and paint particles in the air.

Once you have properly masked off the rusted section, wipe down the area with rubbing alcohol to remove dirt and oil. If you do not have rubbing alcohol on hand, simple soap and water will do, though it does not share the advantage of drying quickly. Before you work on the rust, make sure the entire area is completely dry.

How to Prevent Rusting in the First Place

The best thing you can do to prevent rust on your vehicle is to simply take care of it before it has the chance to form. Here are some tips for keeping your car in good, rust-free condition:

  • When possible, store your car indoors or with a covering. Metal is more likely to rust when exposed to the elements.
  • Regularly wash your vehicle, giving special attention to the undercarriage. Dry it thoroughly and coat it with several layers of wax, especially during the winter months.
  • Clean out drain holes that are designed to keep water from collecting in places that are prone to rust. These areas can get clogged with outside debris, preventing them from doing their job.
  • Chipped or scratched areas are more vulnerable to rust. Repair or cover these areas when possible.
  • If you live in a coastal region or an area prone to snow, make sure you wash off snow and salt from the roads before they accumulate.
  • Regularly inspect your vehicle for rust and treat any sign of corrosion right away. If you catch it quickly enough, you can prevent it from spreading to other areas.

Final Thoughts

In the same way that a cavity eats away at tooth enamel, rust erodes the metal in your vehicle. Taking proactive care of your car is essential for longevity. Though it may seem like an unnecessary hassle, rust-care will save you money in the long run.

According to an AAA survey, drivers spend approximately $3 billion annually on rust repairs, mainly caused by de-icing methods, which can all be prevented with proper, proactive rust care. But in the event your car already has evidence of rust, chemical removers and converters are one of the most simple and effective ways to keep your vehicle looking nice and new.

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