Rust can take over metal surfaces everywhere: cars, outdoor equipment, household appliances, silverware, pipes . . . you get the idea. The development of rust can turn a beautiful object into something unsightly and even dangerous, as the metal slowly corrodes. Metal surfaces are particularly susceptible to rust in moist climates and environments; in these instances it's best to treat metal surface to prevent rust from developing, as outlined in the bottom paragraph of this page. For all other rust problems, you can follow the steps outlined to get rid of rust and repair rust damage your self.
Removing Rust
Remove rust spots as soon as you notice them. The smaller the rusted area is when you get to it, the better. The rust will be easier to remove, and you can prevent further rusting and irreparable damage from corrosion. If you wait too long to remove rust the damage, and repair, will be more noticeable and take longer to finish.
Scrape and sand away rust from the surface. You can use sandpaper, a wire brush, or crumpled aluminum foil to scrape off the surface flakes of rust. This will leave the surface underneath clear and ready for repairing to prevent more rust. For rusted surfaces to big to scrape by hand, use a wire brush attached to a drill, or an industrial sandblaster.
Once you've scraped off the rust, coat the surface with an anti-corrisive primer. Rust-Oleum is a trusted line of paints and sealing coatings designed to protect metal surfaces susceptible to rust damage. The Rust-Oleum Clean Metal Primer is a good specialty primer to apply to metals with some rust damage. Apply a coat of two of the primer to prevent further rust damage and prep the metal for a final coat of paint or sealer (see below).
After priming, paint the rusted surface to remove signs of rust damage. Once primed with a rust-fighting primer, you can paint the surface with any kind of paint you like. Paints designed for metal surfaces will probably work best. You can also find rust-prevention paints designed by brands like Benjamin Moore and Rust-Oleum.
Phosphoric acid is a chemical solution known for its rust removal properties. When applied directly to rusted surfaces, the phosphoric acid converts to the iron oxide (rust) to a water-soluble phosphate compound that is easily scrubbed off. Phosphoric acid is usually available commercially in liquid form, but is used more often as part of a gel, called "naval jelly", which is more applicable to most surfaces. Phosphoric acid is highly toxic and you should always take general safety precautions (gloves, long sleeves and pants, safetly goggle, breathing mask) when using it to remove rust.
Preventing Rust Damage
The best way to stop the spread of rust is to prevent it altogether. Do this by cleaning the surface, then applying a rust-prevention metal primer and/or paint. Use a mineral spirits to clean away grease, dirt, and grime from the surface, then allow the surface to dry before applying products such as Rust-Oleum's Clean Metal Primer and Rust-Oleum's rust-prevention paints.
Be aware of which metals will be more susceptible to rust damage. Thin sheet metal, metal exposed to the outdoor elements, and particular areas of your car (like the wheel wells) will espeically benefit from rust prevention treatments. Taking steps to prevent rust will save you time and money in the long run as you protect your metal surfaces from the corrosive damage of rust.
