Keep the surface wet, the slower it dries the longer it can attack the rust. Application processes will vary, with this product I dumped the desired amount into a plastic container and then applied it to the surface. This same product I also used to clean up the rear differential on my Toyota Tacoma and will be posting a video on that in the future. There are various products on the market, some do work better than others. A chemical rust converter would also be another option which is what I’m using. Using a media blaster would be the best option, however, that can be messy and if you don’t own that equipment, it can be a bit costly to purchase and I’m trying to keep this as a budget repair. Once that rusted metal has been cut out, unfortunately, there will most likely be rust in behind the fender and this can be tough to tackle. Next using a die grinder, clean up the rust hold, cutting out some of that thin rusted metal. Using compressed air, blow out any dirt or debris which may be stuck in behind the fender. Try to clean the area up fairly well, you can go over the area again just before the fiberglass is applied. From the rust damage, there should be about 2” to 3” around that area to ensure we have a solid base and didn’t miss any rust which may jeopardize the repair. Getting the panel down to bare steel can give up a base point of what areas need to be cut out and where the rust ends. We want to avoid heat as it can warp the steel metal. While the surface sander can create heat, if you’re careful it can be minimized. An 80 grit sanding diss will clean up the surface quite quickly. When removing material, it’s also important to wear a mask so exposing yourself to any contaminants is minimal. You can use anything from a surface sander such as what I have here, media blasting, orbital sander, etc. Removing the paint and rust, this can be done by hand or machine done. Luckily the lip is still salvageable so it’ll be easier to maintain the shape and body lines. Unfortunately with this fender design, the inner fender folds along the inside, creating a prime spot for dirt to get trapped, holding moisture and eventually rotting out the steel. So as you can see we have quite a few soft spots along the fender.
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