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Autobody metal rebuilding methods for rust problems

2003

I have recently become interested in automobile restoration and the problems we have with RUST. It seems to me that we should have available technology to solve this problem. Yet when I ask the professionals I find that most seem to be not up to speed in this area... either that or I'm chasing phantoms.

So...

We have ion deposition systems, both hot and cold, vacuum deposition systems and electroplating systems. My questions boils down to a simple one: Is there a practical metal rebuilding system that can effectively rebuild rusty autobody panels?

Perhaps a flame based ion deposition system? Perhaps an electroplating system? Perhaps a solvent based system?

It just seems to me that there should be some safe and simple way to splatter new metal ions onto an old metal surface...

And if we can move the metal about - what metal should we use? Zinc? Aluminum? Nickel? Copper? Maybe one ideal system would be to turn the metal into a plasma and hook an electric gradient between the source and the destination of say a few 1000 volts so we get good impact speeds and use a relatively low influx of ions and a little computer controlled robot that can sit there for a few hours until the job is done. haha.

Terrell Larson
Computer Systems Development - Calgary, Alberta, Canada

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Consider brush electroplating of iron. Relatively easy, low cost chemicals and equipment, low chemical hazard, and the electroplated iron is far more resistant to rusting than the original steel. Rather slow at room temperature, but maybe that's OK for carefully filling ground out areas.

Ken Vlach [deceased]
- Goleta, California
Finishing.com honored Ken for his countless carefully researched responses. He passed away May 14, 2015.
Rest in peace, Ken. Thank you for your hard work which the finishing world, and we at finishing.com, continue to benefit from.
2003

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Someone told me there was a product called rustodian that you can paint on to rusted steel and it will become solid...... Is this true?

C Newman
- Singapore
2005

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I've never heard of "rustodian", C, but "liquid steel" (which seems to be a mix of powdered steel in epoxy) has been around for decades.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey