Hello all. I have been looking for a rust repair guide forever and never found anything that very helpful.

So I am writing this guide or noobs... Why? I am not in any way a mechanic, i am an IT professional and I really hope this help everyone that needs it. So this includes materials needed AND photos.

Tools/materials:

Palm sander (60, 80, 120, 220 grits)
Angle grinder
Bondo glass
Bondo filler
Bondo spreader
Fiber cloth
primer
clear coat
paint (spray or spray bomb)
brake parts cleaner
couple rags
patience and prayer

OK! So lets start with taping off about 4 fingers away from the rusted area. sander 60 grit and sand the area all down to metal upto 2 fingers away from the rust...



Once that is all silver and now bare rust, grab your ginder and grind away the rust... you want to cut away the rusted spot in a square shape (cuz it makes sense and its easier to work with) once you are all finished spray some brake parts cleaner into a rag and wipe away the WHOLE area at LEAST twice. I dont have a pic of what this looks like use your imagination...

Now take your fiber cloth and use your geometry lol... cut a piece of cloth that cover the whole bare metal and try not to go further than the bare metal... (my area was to the bottom of the fender so i had to curve enough to fold underneath which fuse my fender and wheel well together heh)

now get your tin of bondo glass, and just use "eye measurement" to take out the amount of fiberglass you need onto a flat wooden board or something, you will have some left over after this no biggy. now get your cream hardener that was hidden in the tins cap and put a line across the goop you just scooped out (for every "fistfull" there should be a "pinky line") the more you put on the faster itll harden.

Mix it ALL up quick with your spreader, and start by spreading right lined upto where the metal starts, one your rust is surrounded by the goop take your fibercloth and stretch and press it on, then take the rest of the goop and cover the WHOLE fibercloth. After you are done take 20-30 mins and let it dry.

Take a body file and file of the raised goop, take a razor and cut away any long fiber cloth that is sticking out. then take your 80 grit and work away to take away the roughness at a slight angle. once your roughness it rounded out then flatten your sander and start smoothening the area... patience, this can take a while, keep on feeling it, until you are comfortable with the smoothness and shape.



now for the filler, make sure the goop is off the board and the speader, your a razor to skin it off. now mix your filler with its hardener and apply to the area covering even bare metal on good stokes and build a decent shape, dont worry about steaks.

http://i43.tinypic.com/ie4d1f.jpg

take another good break... (key thing i guess i should have mentioned is, you can always test the goop left over on the board to see if its dried sufficiently instead of trying to be careful and touch it on the car)

now 80 grit the area flat, and feather out the edges at slight angle. again patience young palm sander, perfection will come... start shaping the area as needed. when its so smooth you want to rub your face on it, take your 2000 grit and wet it, and start wetsanding all the filler...

http://i40.tinypic.com/14n38km.jpg

once this area is smooth, shaped and makes you smile... its time for the primer... get the news paper and tape away the area... spray the primer back and forth in strokes so there is no runs, when you see its nice and wet, then let dry for a few mins then hit it again (i did about 2-3 thin coats)

once dried, hit the area with your color paint in the same manner (i did about 3 coats and then sprayed certain areas from a distance) this is going to take a good 30-45 mins to dry.

once dray hit it with 2 thin coats of clear coat... and wala!





Hope this helps. have fun!

 

Nice dude! that's a killer walk through for something that's good for anyone to know! Thank you!

 

You are quite welcome. I just wish I had more pics that's why I tried to be as detailed as possible.