No Welding Required Rust Removal in 7 Easy Steps

Step 1: Remove the surface rust as best as you can with an orbital sander.

Step 2: Cut the rust out with a file sander. Be sure to get into the nooks and crannies as best as possible.

Step 3: Spray a rust neutralizer all over the area where the rust was.

Step 4: Neutralize the rust remover and allow the area to dry completely.

Step 5: Use your body filler and rebuild the area.

Step 6: Sand down the body filler until the desired body shape is achieved.

Step 7: Prep the repaired area with a degreaser (I like to use 90% isopropyl) and then spray the repaired area with primer.

Download the full list of products I use and get a link to the videos so you can see this repair in action.