Ford F-150/F-250: How to Fix Rust Spots

Rust could ruin the value of your Ford F-150 or Super Duty tremendously. Here are a few steps you can take to fix rust and prevent it from happening.

By Makeda - October 22, 2014

This article applies to the Ford F-150 (2004-2014) and the F-250, F-350 Super Duty (2005-2014).

The worst thing about rust is that it spreads. So the longer you ignore it, the more rust you will have to deal with. We will walk you through everything you need to know about rust. But first, get into the habit of washing your car every two weeks. Below are the steps you need to take to avoid having to deal with rust, and if it's too late, we will show you how to fix rust spots.

Materials Needed

  • Gloves
  • Safety glasses
  • Dust mask
  • Painters tape
  • Dual action sander (80-150 grit)
  • Metal grinder (120 grit sandpaper)
  • Primer
  • Rust removing acid
  • Paint thinner
  • Sandpaper
  • Paint

How to Remove Rust

Step 1 - Tape off the rusted area

Before you begin, put on your gloves, dust mask, and safety glasses. That's a good way to avoid getting rusty cuts like the guy in the photo below.

Figure 2. Mark the rusted area.

Protect the area surrounding the rust spot by covering it with painter's tape and newspaper.

Step 3 - Sand down the paint

Figure 3. Dual action sander.

Take the primer and paint off of the car by using a dual action sander (80-150 grit) as seen in Figure 3 above.

Step 4 - Grind down the rust

Figure 4. Remove the rust with the metal grinding wheel.

Use a metal grinding wheel to take off the thick rusted areas, moving over them slowly. After you are done, use rust removing acid such as Evapo-Rust.

Step 5 - Spread paint thinner

Figure 5. Spread paint thinner.

Wipe over the rusted area with paint thinner.

Step 6 - Spray Lubricant

Figure 6. Spray lubricant.

After cleaning the surface from the rust, spray a lubricant or have it painted with a protective layer of paint by a professional.

Step 7 - Spray rust prevention spray

Figure 7. Spray rust prevention.

Rust prevention sprays are available at auto body shops and will protect your car for a certain period of time from salt, exposure to water, snow, etc. Use it after you are done with the steps above.

How to Prevent Rust

Step 1 - Always dry your car

Figure 8. Wipe dry.

To prevent rust, after having your car washed, make sure to keep the surface dry by wiping it down and protecting it with wax. You can use paint or lubricant on the underside.

Step 2 - Regularly check for rust

Figure 9. Check for rust.

Regularly check for rust for instance, paint bubbles or blisters in the paint is a sign of rust, and it is time to get your car treated. Do your best to keep the interior clean as well. If you drop liquid (water, coffee, soup, etc.) in your Ford F-150 or Super Duty truck, make sure to clean it to avoid rust on the inside.

Pro Tip

  • Check for rusts on the engine, trunk and external painted areas
  • Quickly fix small rust spots
  • Remove rust in the interior of your car with sprays

Featured Video: How to Fix Minor Rust Spots

Related Discussions