What can I put on my truck to stop rust?

Rust is one of the biggest enemies for truck owners. It can quickly damage your vehicle’s body and frame, leading to expensive repairs or even forcing you to scrap the truck entirely. Thankfully, there are several effective options you can use to prevent, control or stop rust on your truck.

Understanding Truck Rust

Before looking at solutions, it’s helpful to understand what causes rust in the first place. Rust is the result of metal oxidizing when it’s exposed to oxygen and moisture. On vehicles, it most often attacks the sheet metal of the body and the steel used in the frame and other components underneath the truck.

Road salts, dirt, grime, and even tiny metal particles from normal wear will stick to your truck’s paint and chrome surfaces. Over time, these can abrade away the protective coatings. Once the underlying bare metal is exposed, oxidation begins. On the frame, corrosion often starts from the inside out where condensation and dirt collect in unseen spots.

Rust needs three elements to form – iron, oxygen, and water. Since steel and iron are obviously present on vehicles, controlling exposure to air and moisture are the keys to prevention. But once rust has started, you need products that can stop or slow ongoing corrosion, stabilize damage, convert rust into inert materials, or physically remove the rust itself.

Washing and Waxing Your Truck

One of the most important rust prevention steps is to regularly wash your truck and apply wax or other protectants. This clears away corrosive contaminants before they can start damaging paint or chrome.

When washing, pay close attention to the underside, wheel wells, and bumpers where mud and road grime collect. Hose off debris and then use a soap and brush to scrub remaining dirt away. Rinse thoroughly and wipe down all surfaces that you can reach.

Wax or other protectants add an extra layer of waterproofing to keep rust-causing moisture away from the metal underneath. Typical car wax works well for painted body panels. Special waxes or anti-rust coatings are made for bare chrome surfaces on bumpers, trim, wheels, etc. Undercoating sprays can reach the frame and components underneath.

Tips for Effective Washing

Inspect paint for chips or scratches that expose metal and touch them up after washing.
Remove stubborn grime or road tar with solvents or an atomizer before soaping up.

Use microfiber mitts and towels to avoid scratching paint as you wash and dry.
Dry the entire truck, including underneath, to prevent moisture buildup.
Wax at least every 3-6 months to maintain protection.

Surface Rust Removers

If you already have some light surface rust, there are chemical products that can help reverse or remove it. Used promptly, these can stop rust in its early stages before it threatens the metal underneath.

Phosphoric Acid

Phosphoric acid converts reddish iron oxide to black ferric phosphate through a chemical reaction. This stops the rusting process and stabilizes the damage. The conversion leaves a black protective coating.

Phosphoric acid is safe for cleaning light rust on truck exteriors, chassis components, etc. Wipe or spray it on, let it sit for a few minutes, then rinse off. The acid is mild enough that it normally won’t damage paint.

Rust Removers

Solvent-based removers use chemicals like oxalic acid to dissolve rust so it can be wiped or scrubbed away. They’re effective for removing loose rust from truck bodies without harming paint and other coatings.

With light surface rust, you may need to agitate with a brush and reapply the remover several times to get back to clean metal. Powerful gels and sprays are available for vertical or hard-to-reach surfaces.

Molasses Rust Removal

An interesting DIY rust removal trick uses molasses diluted with water. The molasses reacts with rust to create iron phosphate compounds similar to phosphoric acid. After letting it soak for a day, you can scrub off the dissolved rust.

Molasses works best on lightly rusted items that can be soaked. Wiping or spraying on large truck surfaces would use far too much. But it’s fine for components like brackets, pulleys, nuts and bolts removed during repairs.

Rust Converters

Another option for existing rust is converting it to a protective coating using special chemicals. Rust converters change iron oxide into iron tannate, a dark material that halts the rusting process and stabilizes damage.

Applying converters is similar to rust removers. Coat the rusted area, let it sit for a few hours, then rinse any residue. The iron tannate remains as a primer coat that you can paint over.

Converters have advantages over removers for dealing with rust pits and scaling corrosion. By chemically changing the rust itself, they can stop the process even where you can’t scrub off all the oxidation.

Rust Prevention Sprays

Clear coatings formulated to prevent rust provide an invisible barrier against moisture on both painted and bare metal surfaces. Typically based on waxes, oils, or resins, they can be applied almost anywhere on your truck.

On the exterior, a rust preventive spray is a quick way to protect vulnerable underbody areas, seams, and exhaust components that are hard to wax. Reapply after washing to keep these spots sealed.

The sprays are also great for interior usage. Coat metal parts underneath the hood and chassis to ward off corrosion from condensation or minor drips. You can use them on battery terminals, trailer hitches, suspension components and any other exposed metal.

Common Types of Rust Prevention Sprays

Oil-based – Provide good moisture protection but tend to wash off over time.
Wax-based – Soak into pores and lasts longer than oils.

Resin/polymer – Form a durable plastic coating that won’t wash off.
Rubberized – Flexible coating that prevents rust and deadens sound.

Rust Repair With Paints and Coatings

For body panels with significant rust damage, specialized paint products are available to repair it without removing all the metal. By stabilizing corrosion and building up protective layers, they can extend the life of rusted truck body panels.

Rust Encapsulators

Encapsulator coatings have flexible resins that adhere to rusted metal and seal in the rust. This stops oxidation and prevents further spreading beneath the paint. After cleaning the area, brush encapsulator on heavily rusted spots before applying primer and paint.

Rust Converting Primers

These primers contain chemicals similar to phosphoric acid or rust converters to turn corrosion into an inert protective barrier. The converted rust stabilizes the damage and improves adhesion for paints applied over it.

Converting primers can be used directly on rust or over encapsulators. They chemically convert any remaining oxidation and create a base layer for the final finish coat.

Rust-Resistant Enamel Paints

Specialized enamel paints contain rust-inhibiting additives along with extra resins and binders. This boosts their adhesion and provides a moisture barrier coating over repaired rust spots.

Using rust-resistant enamel as your topcoat provides maximum protection and durability. Opt for quality single or two-part paint systems intended for automotive use.

Professional Rust Repair Services

For severe rust with extensive damage or holes in body panels or the frame, professional repairs may be the most effective solution. Experienced auto body shops have intensive rust repair techniques and paint systems not feasible for DIY use.

Metal Panel Bonding

Panels with severe rust can be repaired using metal bonding techniques. The damaged section is cut out. A replacement piece of sheet metal is chemically welded into place with special adhesives.

Since cutting and welding aren’t needed, bonding preserves the original strength of the surrounding metal. The bonded panel is ground flush, sealed from behind, and restored to a like-new finish.

Rust Cavity Filling

For rust holes and damaged areas that can’t support a patch, body shops inject expanding foams or resins to fill the cavities and seal out moisture. Once cured, the foam provides a solid base for primers and paints.

Cavity filling stabilizes damage caused by advanced rust-through on body panels and supports weakened sections on truck frames. Combined with rust converters, it can add years of life to severely rusted components.

Frame Repairs

Extensive frame or undercarriage corrosion may require cutting out and welding in new metal to repair damaged sections. Truck frames can also be reinforced or partially replaced with bolted-on supports.

Frame rust repairs are time-consuming and costly but worthwhile for valuable vehicles. Shop rates typically range from $100 to $150 per hour.

Replacing Rusted Parts

In some cases, removing rusted components and replacing them may make the most sense. This is often true for heavily corroded or structural parts that would be hard to repair in place.

Common truck pieces replaced due to rust include:

Body panels – Fenders, doors, bed sides, etc. New panels should be sealed and undercoated.

Exhaust system – Mufflers, pipes, catalytic converters.
Fuel tank and lines – Severe rust can cause leaks.
Brake and suspension parts – Calipers, control arms, sway bar links.

Wheels – Peeling chrome or severe pitting weakens wheels.

Evaluate the cost of replacement parts compared to potential repair time and effort. Swapping common body panels may make more sense than trying to rebuild them.

Used Truck Body Panels

One way to save money on replacements for rusted panels is to buy used parts. Many auto salvage yards specialize in old truck models and stock body panels ready to bolt on.

Check for any collision damage or rust on the used panel itself. Make sure to compare part numbers so you get an exact fit. You’ll still need to seal, prime and paint a used panel.

Pulling parts from a junkyard donor vehicle yourself can yield major savings. This works if you have access to such trucks and the skills to remove panels undamaged.

Preventing Rust When Repairing or Replacing Panels

To avoid having new panels rust out again, proper preparation and protection are key. Here are some expert tips for keeping repaired areas rust-free.

Remove all old sealers and undercoating from the repair area.
Seal exposed seams and edges with corrosion resistant primers and seam sealers.
Coat enclosed cavities with rust-preventing sprays before closing them up.

Use high-quality primer, basecoat, and clearcoat paint systems.
Consider applying cavity wax inside enclosed panels through access holes.
Reseal any openings with high-temp silicone once work is done.

Taking extra care will help prevent renewed rust. Maintain your truck’s exterior to keep the new panels protected.

Rust Protection for New Trucks

If you’re buying a new truck, get the most intensive rust protection package offered by the manufacturer. New vehicles already have excellent anti-corrosion coatings, but extra protection enhances this.

Spray-on bedliners also help shield the bed from moisture damage. High-quality aftermarket rustproofing adds layers of defense that will pay off for years.

Consider options like:

Undercoating – Coats the entire underbody and suspension.
Seam sealers – Seal all seams and joints.

Rust inhibitors – Sprayed inside enclosed cavities.
Wheel well liners – Protects wells from road debris.
Stone guard film – Applied to vulnerable lower panels.

The small extra cost when new provides protection that would be far more expensive later. Maintaining your new truck according to the manual will also help keep rust away.

Pickup Truck Rust Prevention Tips

Beyond using rust-fighting products, smart maintenance and parking habits will help reduce corrosion on your truck. Here are some useful tips.

Wash regularly to remove salt, dirt and road grime before they cause damage.

Inspect for paint chips and touch up quickly to prevent rust spots.
Park on gravel or grass rather than asphalt or concrete when possible.
Avoid parking under trees – sap and dew drip cause etching and rust.

Check undercarriage components for buildup and wash after off-roading or winter driving.
Lubricate suspension and chassis parts so dirt washes off rather than sticking.
Have frame and underbody steam cleaned or rinsed annually for hard-to-reach areas.

Putting a little focus on prevention goes a long ways towards keeping your truck solid and rust-free for many miles.

Conclusion

Rust can threaten the life of your pickup truck. But with a quality protective regimen and prompt attention to early signs of corrosion, you can keep it looking great and running reliably. Using a combination of deterrent and repair products, along with good maintenance practices, provides the best protection.

Washing and waxing are first lines of defense. For surface rust, removers, phosphoric acid, or converters can halt damage. Rust-resistant paints and professional repairs combat more severe corrosion. And remember to address problem areas quickly to stop rust in its tracks.

Keeping that ugly orange plague at bay takes diligence. But making the effort will help your truck stay solid, safe and road-ready for many miles down the road.