repair rust on car

Start by diagnosing the flavour of misery: surface rust can be saved; bubbling and holes mean surgery; structural rust is a professional’s problem, not a weekend hobby.

For light rust, grind or sand to bright metal, treat with a phosphoric rust converter, then epoxy prime, colour coat, and clear—mask like a pro or you’ll invent new shades of overspray.

Perforation needs metal replacement: cut out, weld in a patch, only then skim with filler, sand, prime and paint; finish with cavity wax so it doesn’t come back like a bad sequel.

Keep sparks away from fuel lines, wear a respirator and goggles, and for the love of rego, don’t ignore rust near seatbelt mounts or suspension points.

In Australia, obvious structural rust can fail a roadworthy and spook insurers—do it properly or get a panel shop to do it once.