Using an electric grinder to remove rust.
Rust, also known as iron oxide, is very damaging to metal, especially cars. Rusting is a natural chemical process that occurs when metal is exposed to damp air. When moisture and oxygen touch the iron in metal it forms rust. Rust damage usually starts from a scratch or dent in the finish that is covering the metal. If left unchecked, a small rust hole will occur and it will get larger until it is impossible to repair. Fix small rust holes as soon as possible to prevent the rust from spreading and making the hole larger.
Instructions
1. Inspect the item that has the rust hole to locate all of the areas that are rusting. Do not leave any rust on the metal or it will rust over again. Look for areas where the paint is bubbling or lifting; there may be rust underneath.
2. Measure the size of the hole. A small hole is considered anything smaller than two inches. A hole larger than that size will require other methods of repair.
3. Place a tarp on the ground underneath the item that will be fixed. Cover the other parts of the item that are rust free with plastic sheeting. In other words, if you are removing rust on a vehicle, secure plastic sheeting over the parts of the car that are in good condition.
4. Sand the area around the rust hole with an electric hand-held grinder. An electric grinder will make the job easier, if you don't own one use heavy sand paper and a wire bristle brush to remove the rust. Scrape away loose paint and all the rust that is surrounding the rust hole until it is completely gone.
5. Apply a rust-removing solvent around the hole to make sure all traces of the rust are gone. Follow the manufacturer's directions and apply it to the front and backside of the metal, including the interior of the hole.
6. Wipe down the surface surrounding the hole with a clean dry cloth. Make sure there are no specks of dust, rust, or paint any where on the metal.
7. Apply a fiberglass fill, or bonding compound, over the hole. If the hole is small you should be able to apply the bonding fiberglass fill over the hole on it's own with no support. If the hole is larger, place a small piece of wire mesh over the hole, and then apply the fiberglass fill. Follow the directions on the container of bonding fiberglass compound you are using. Allow it to dry the specified amount of time.
8. Sand the bonded area with a piece of sand paper until it is smooth and even with the existing metal around the hole. Clean the dust off the metal and the bonded hole with a brush and a dry cloth.
9. Prime the bonded hole and the exposed metal with a primer. Paint the bonded hole and the unprotected metal with spray paint. Follow the manufacturers directions for use and dry time. All of the exposed metal should be covered with paint, so the rust will not reappear.
Tags: hole with, rust hole, bonded hole, fiberglass fill, hole larger