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Old 06-17-2011, 09:43 AM
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Rust removal and treatment in the UK - Epoxy Primer - help/advice please

Hi All,

I'm intending to do some DIY rust repair on my car, and after scouring the internet you HotRodders seem like the people who really know there stuff on getting rid of rust. I'm really hoping you could offer some advice, so that I can start on my little project, and achieve a good result.

I've read many threads/posts at length in particular this: secrets of surface rust removal revealed and would now like to ask a few questions and some translation of things suitable for the UK.

The area I will be tackling that has rust is the underside wheel arches of my car - so quite a small area. Therefore, I don't want to spend too much money as I won't be using the items greatly. The car is a 1999 standard coupe - unfortunately not a fancy hot rod.

So having read's my plan and I'd be most grateful for your comments/input/answers/criticism.

The Game Plan

Step 1: Sand the Rust
Using this: connected to a drill, sand out all the rust.

Then using 80 grit paper, try and get back to shiny metal. Using a wire brush as well.

Step 2: Naval Jelly/Phosphoric Acid
I have neat liquid phosphoric acid. But due to the location of the problem (and the fact that I cannot remove the panels as the rear arches would involve dismantling half the car) I am worried that the phosphoric acid will just run off. I could west a rag and rub it on?

Assuming I use Naval Jelly - work this into the rusted area using wire wool/a wire brush.

-Keep the naval jelly wet with mists of water.
-Remove with a mist of soapy water and dry with paper towels.
-If any deposits are left remove with wire brush.
- Repeat as necessary. Till there is only shiny metal.

Step 3: Sand with 80 grit paper (dry)
As a key for the primer.

Step 4: Wax and Silicone Remover
I don't know what you guys eman by this? Is this like methylated spirits? Ot is it a speciality product?

Step 5: Epoxy Primer
My initial intention was to use Bonda Primer with Zinc, at this point, but having read up it seems epoxy is the preferred method.

I have had great trouble locating this in the UK - any leads?
Does it only come in tins? I will not be needing much and don't want to splash out on getting spray equipment.
Or can I paint it on in thin coats?
I have heard talk of spray cans, but haven't seen a review based on actual use.

How many coats should I use, and how long before each coat?

Step 6: Sand with 180 grit paper (dry)

Step 7: Two Pack Primer
I haven't seen this available in aerosol cans - is it?
Is anything on this page appropriate:

Give two coats, 20 mins between each.

Step 8: Sand with Very Fine paper
Once primer is dry flat back with 600 wet sand paper

Step 9: Paint
I have this, is this ok:
Two coats (short time between each to dry) to cover repair. Then Third

Step 10: Clear Coat Lacquer
- 30-45 mins after 1st coat of paint - two coats of lacquer.
I have this, is it ok:

Step 11: Farcela G3
Cutting compound for any blending

The "Lip" of the wheel arch

My other issue is what to do with the lip of the wheel arch. I.e. the curved bit that collects all the dirt and mud, and is what starts the rust.

My thoughts are to do as above up to Step 7. And then cost with Stone Guard Pint, like this:

Any other ideas?

I would be most grateful for your responses and thoughts on the above.

Thank you,

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Old 06-17-2011, 10:09 AM
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Why not sign up at and get info closer to your home ?

Sometimes there are issues getting paints shipped to the UK by an individual.
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Old 06-17-2011, 10:11 AM
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Must say that this throws using epoxy into doubt: Having problem with epoxy primer......

Maybe I could use a hairdryer, givn the small-ish area I will be concentrating on? But I could only hair-dry it for a certain duration.

I've only got a small garage, not access to heated room.
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