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Fighting with rust #5427760 05/12/20 10:15 PM
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CDX825 Offline OP
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I'm currently working on replacing the floor in my 98 Ranger because of rust. Ive sand blasted both the inside and underside of the cab multiple times to try and clean up what good metal is still there. The problem I'm having is the metal is super porous because of the rust and the blasting is not getting deep into the porosity of the metal. So even if I paint it or prime it the rust ends up coming back through. Ive tried multiple rust converters and primers and nothing seems to put a stop to it. Its getting old fast.

Anyone have any solutions? I figure anyone that has blasted super rusty metal has probably experienced the same thing.


1984 Ford F250 6.9 Diesel C6 2WD Rotella T 15W40 NTZ Bypass Filter

1992 Mazda B2600 4x4 Amsoil Series 3000 5W30

1998 Ford Ranger 4x4 Pennzoil Platinum 5W30

Re: Fighting with rust [Re: CDX825] #5427779 05/12/20 10:58 PM
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jeepman3071 Offline
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What rust converters and primers have you tried? I've had great success with Chassis Saver and POR-15 on Jeeps when it is prepped correctly. It's not cheap, but it works.


1998 Jeep Wrangler Sahara 4.0L/5MT (157k) - PHM 10w30, Wix 51085
2009 BMW 328i N51 (61k) - Liqui Moly 5w40, MANN HU816X
Re: Fighting with rust [Re: CDX825] #5427781 05/12/20 11:01 PM
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PowerSurge Offline
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Try rust-mort. If that won’t work, move south.


1993 Porsche 964, 2001 Ford SVT F-150 Lightning, 2004 Chevrolet Corvette, 2018 Toyota Tundra and a few others
Re: Fighting with rust [Re: CDX825] #5427806 05/13/20 12:58 AM
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joegreen Offline
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Have you thought of an oil undercoating. I make this homemade grease undercoating and it works fantastic at slowing down or stopping rust. Btw I have a 98 Ford ranger and the entire underside of the vehicle has been coated for 3 years and it's working fantastically.


1978 Chevrolet k20
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Re: Fighting with rust [Re: CDX825] #5427820 05/13/20 02:34 AM
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xnicke Offline
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I fear that you at best only can slow it down. If it is that porous the only way is to replace the metal. frown

Re: Fighting with rust [Re: CDX825] #5427835 05/13/20 03:53 AM
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Surestick Offline
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Wire brush on a drill/grinder before sandblasting to remove the thicker rust?

Re: Fighting with rust [Re: CDX825] #5427847 05/13/20 04:22 AM
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dlundblad Offline
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Can you post photos?


03 Jeep WJ 4.0 208k
02 Volvo S60 2.4T 199k
97 Chevy Blazer 4.3 175k
04 Audi A4 3.0 210k

Re: Fighting with rust [Re: joegreen] #5427904 05/13/20 06:54 AM
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pbm Offline
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Originally Posted by joegreen
Have you thought of an oil undercoating. I make this homemade grease undercoating and it works fantastic at slowing down or stopping rust. Btw I have a 98 Ford ranger and the entire underside of the vehicle has been coated for 3 years and it's working fantastically.


Can you give us the recipe for your homemade undercoating?

I made a homemade undercoating out of wax from a toilet bowl wax ring*...bar and chain oil (motor oil works too) and mineral spirits. It's a variation of a recipe that I read about on this site. It doesn't spray well because of the wax so I brush it liberally on the underside of the vehicle....seems to work pretty well.

* The toilet ring wax was the type recommended by the original thread (as opposed to candle wax)....I think he called it parafinic wax

PS: If you use POR-15....only buy the amount you can use soon....it does work well but I've never
been able to store leftover amounts without it hardening.


'Journalism is Dead'
Re: Fighting with rust [Re: CDX825] #5427927 05/13/20 07:24 AM
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Donald Online Content
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The rust protection products like CarWell or Krown or FF or NH Coatings creep and should prevent new rust.


2015 Ford F-250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: Fighting with rust [Re: CDX825] #5427940 05/13/20 07:37 AM
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izualangel Offline
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I've had great luck with POR-15 in many applications. Just get the surface prep done well. I've been able to save extra by putting Saran Wrap between the can and lid, and then pushing it closed.


2006 Subaru Outback 2.5i - Mobil 1 5w-30 HM with WIX 57712
2019 KIA Forte 2.0L - Mobil Super 5w-20 with OEM filter
Re: Fighting with rust [Re: CDX825] #5427952 05/13/20 07:49 AM
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doitmyself Offline
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I agree with joegreen and Donald. Unless you can get a primer/paint system to be 100% coverage, air and moisture will wick in from any crevice, etc. and creep underneath the paint to reactivate the micro rust that you failed to remove.

I , too, have mixed results with rust reformers. I either use one of the "wetter" phosphoric acid based ones or the creamy tannic acid based ones that form a polymer coating. One surprising result I am testing more is the old Rustoleum fish oil based red metal primer ( I don't think the aerosol version is the same???). I've had some remarkable results with the brush on Rustoleum rusty metal primer. Go figure. But again, if moisture and oxygen can creep in under the paint from an unprotected seam, crevice, etc. the rust will return.

A creeping, non (hard) film forming oil that penetrates the "spongy rusted steel" and all crevices seems like the best solution. Apply it several times annually. Trav recommends a commercial product.....can't remember the name.

Put well-type liners inside the cab to eliminate moisture (Weathertech, etc.)

Last edited by doitmyself; 05/13/20 07:50 AM.
Re: Fighting with rust [Re: CDX825] #5428001 05/13/20 08:29 AM
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JohnG Offline
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https://industrial.sherwin-williams...396/macropoxy-920-pre-prime.9896905.html

I use this stuff (and so does NASA). It is also available in smaller sizes on special order. It's a 2 part epoxy, clear.

Re: Fighting with rust [Re: CDX825] #5428002 05/13/20 08:32 AM
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MarkM66 Online Content
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What sand blaster and sand are you using?

Sandblasting is ideal for rust pores.

Re: Fighting with rust [Re: CDX825] #5428151 05/13/20 10:54 AM
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Dave9 Offline
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If you can't get enough off (and still have enough metal left) with an angle grinder and flap wheel, it's time to cut it out and weld in new panels. I hate rust.

Re: Fighting with rust [Re: MarkM66] #5428162 05/13/20 11:12 AM
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dave123 Offline
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Originally Posted by MarkM66
What sand blaster and sand are you using?

Sandblasting is ideal for rust pores.

+1

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