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Axle rust

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Old Nov 1, 2025 | 07:35 PM
  #1  
ArticTheWolf's Avatar
ArticTheWolf
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Axle rust

Posted this in the brakes suspension tires wheels section but I’ll put it here too since this is the correct spot for this truck

long story short my stepdad has a 2003 f350 on its last legs and once it gets replaced I’m planning to steal the axles off it refurbish them and put them on an OBS once I get one

was out there earlier looking at this and saw this scale buildup around the housing (ik I have to replace leaf spring components and diff cover) but is the axle tube usable with this amount of rust and scale? (Side note how thick are the walls of the axle tubes)



 
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Old Nov 2, 2025 | 12:04 AM
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99f350sd
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Been there done that... Needle scale and or industrial sand blaster. Then use rust bullet system...Both of my axles are done and were as bad...I have a Dana 60 front I have to do the same thing to to replace my dana 50..
 
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Old Nov 2, 2025 | 06:57 AM
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Overkill2
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There is also Chassis Saver from Magnet Paints. I just did my rear wheel wells, cut out the driver's side inner wheelhouse completely and just took out enough on the passenger side to get the foam that Ford and the others put in the rear wheel wells out. With Chassis Saver you don't have to remove the rust completely. Get all the loose scale off and get down to tight rust. Can use a wire brush and/or wire wheel. This paint is tenacious AF. It cures by moisture. It will weld the can top to the can if precautions are not taken. I bought cheap plastic paint cans with snap on tops to put the paint in after dealing with, you guessed it, glued on paint can lids. I then use a plastic sandwich bag on top of the can, then put the lid on.

It will also stick to properly prepped good paint, sanded with 120 to 180 grit sandpaper. But it stick to the tight rust. Use some elbow grease to get that scale off, or it could be sandblasted as well, because then it's not smooth and new metal, Chassis Saver would probably stick to it. The key with CS is to get at least 4 coats on, for complete coverage, to prevent any small pin holes in the paint that would prevent water from getting back in.

Here's my thread here. If you want any more info, let me know if you want more pics. I have experience with CS and can offer info if you decide to go with it.

 
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Old Nov 2, 2025 | 07:27 AM
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ArticTheWolf
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Originally Posted by 99f350sd
Been there done that... Needle scale and or industrial sand blaster. Then use rust bullet system...Both of my axles are done and were as bad...I have a Dana 60 front I have to do the same thing to to replace my dana 50..
never heard of rust bullet what's that if you dont mind me asking? a rust inhibitor?
 
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Old Nov 2, 2025 | 12:33 PM
  #5  
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Overkill2
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Originally Posted by ArticTheWolf
never heard of rust bullet what's that if you dont mind me asking? a rust inhibitor?
Similar to Chassis Saver. I've heard of it before and have checked it out but I can't remember if I've used it but it sounds very similar to Chassis Saver.

https://www.rustbullet.com/


 
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