The Best Way to Refinish a Rusty Truck Frame
If you have a rusty car or truck frame that you want to refinish and restore, you might be wondering what the best way is to go about doing the restoration. Customers contact us all day long with just that question: RustSeal or KBS Rust Converter? Below we break down the difference between the two and which option is the best way to refinish a rusty truck frame.
| Quick Answer: For the longest-lasting rust protection, RustSeal is the best option, applied after prepping the surface with KBS Klean and RustBlast. KBS Rust Converter is a faster, lower-labor option that works well on completely rusted surfaces, but RustSeal provides the longer-lasting, more durable finish. |
What is RustSeal?
RustSeal is a rust preventive coating with a finish quality that is smooth and looks a lot like a ceramic coating. RustSeal is extremely hard and durable yet flexible enough to avoid chips, scratches, cracks, and peeling, and it is available in many color options. RustSeal is an incredible permanent solution for rust prevention.
How Does RustSeal Work?
Exposed metal + moisture + oxygen = rust. RustSeal works by separating metal from moisture and oxygen. It can be applied to bare, rust-free metal or applied directly to treated rust to encapsulate and stop it. RustSeal is formulated to grab onto metal and stay put, forming a permanent, non-porous barrier against moisture and oxygen. This strong adhesion, combined with RustSeal's flexibility, allows it to take severe impacts without chipping or cracking, which preserves that barrier. These qualities make RustSeal a great coating to refinish a rusty truck frame that might see hard off-road use.
How Do You Apply RustSeal?
Proper preparation is the key to getting the best adhesion of RustSeal when refinishing a rusty truck frame. KBS Coatings has put together an all-inclusive, three-step system to clean, prep, and seal the metal for the best results.
Step 1: KBS Klean
After removing loose, flaky rust with sandpaper, a scotch brite pad, or a wire wheel, the next step is to use KBS Klean to clean the surface. KBS Klean is mixed with warm water, and the surface is washed down with the solution using a scrub pad or bristle brush for the best results, then rinsed off with water. KBS Klean is a powerful, concentrated cleaner that works great to remove dirt, grease, and grime. Full directions for using KBS Klean can be found here.
Step 2: RustBlast
Next, RustBlast is used to neutralize any remaining rust. To provide the best adhesion for RustSeal, RustBlast etches the surface and leaves a dusting of zinc phosphate. It is sprayed directly on room-temperature or warmer metal and kept wet for at least 30 minutes, or longer depending on the extent of existing rust, and the surface can be scrubbed with a scrub pad during this time. Keep in mind that RustSeal can encapsulate treated rust, so it isn't necessary to remove every bit of it. When done, rinse the metal with water and dry it thoroughly. Full directions for using RustBlast can be found here.
Step 3: RustSeal
Now that the metal is prepped, it's time for RustSeal. It can be brushed, rolled, or applied with simple spray equipment. Whatever the method of application, apply RustSeal in thin, covering coats, allowing approximately 2-6 hours of dry time between each. RustSeal is moisture cured, meaning moisture in the air helps it cure - the higher the humidity, the quicker it cures. Detailed directions for using RustSeal can be found here.
What is Rust Converter?
KBS Rust Converter is a convenient aerosol spray made with tannic acid that transforms iron oxide (rust) into a bluish-black ferric tannate inert primer layer that resists moisture. It kills existing rust and stops new rust from forming.
How Do You Apply Rust Converter?
KBS Rust Converter is designed for use on rust, but not on non-rusty surfaces or surfaces with a mix of rusty and non-rusty areas.
Surface Preparation for Rust Converter
- Remove as much loose, flaky rust as possible with a wire wheel or sandpaper.
- If needed, wash the surface with KBS Klean mixed with warm water, using a scrub pad or bristle brush for the best results.
- Rinse the surface with water and dry it thoroughly.
Rust Converter Application
- Spray KBS Rust Converter with steady, even strokes 8 to 12 inches from the surface.
- A chemical reaction will cause the rust to turn black.
- KBS Rust Converter is dry to the touch in about 10 minutes, and a full cure takes place in about 24 hours. Thick coats may take a little longer.
- If a second coat is needed, wait 24 hours for the first coat to dry.
- Full directions for using KBS Rust Converter can be found here.
Top Coating Rust Converter
While KBS Rust Converter can stand alone, it also acts as an excellent primer for oil, acrylic, and epoxy-based paints. If you choose to use Rust Converter to refinish a rusted truck frame, you can top coat it with something like BlackTop for a better appearance.
What's BlackTop?
BlackTop is a single-stage, high-performance, moisture-cured, one-part UV-stable coating with a beautiful black finish. It's ideal for top coating surfaces previously sealed with any paint or primer system, and it can also be applied directly to bare metal without the need for a primer.
Surface Prep for BlackTop
- If KBS Rust Converter is fully cured and hasn't collected any dirt or dust, BlackTop can be applied directly to it without any preparation.
- If there is dirt, grease, or grime on the Rust Converter, wash the surface with KBS Klean mixed with warm water.
- If KBS Klean was used, rinse the surface with water and dry it thoroughly.
BlackTop Application
- BlackTop can be applied with a brush, roller, or simple spray equipment.
- Apply 1-2 thin coats.
- Re-coat once the previous coat is dry to the touch and doesn't leave a fingerprint, and before 24 hours have passed. If you go more than 24 hours, lightly scuff the previous cured coat with 320 grit or a green scotch-brite pad first.
- Full cure for BlackTop is 48 hours.
- Full directions for using BlackTop can be found here.
What's Better: Rust Converter or RustSeal?
| KBS Rust Converter | RustSeal |
|---|---|
| Saves labor time - preparation is minimal and application is quick | Longer-lasting, permanent protection designed to last the life of the vehicle |
| Transforms rust into a hard, paintable primer layer | Extremely durable and flexible, keeps metal sealed |
| Stops rust | Encapsulates and permanently stops rust |
| Convenient aerosol format (RustSeal can also be sprayed with the Preval Sprayer Kit) | Works on lightly rusted and non-rusty bare surfaces, including preemptive protection |
| Coarse surface texture | Smooth finish that looks like powder-coating, with far more durability and flexibility |
So, What's the Best Option for Refinishing a Rusty Truck Frame?
For the ultimate, longest-lasting rust protection, we always recommend RustSeal, first preparing the surface with KBS Klean and RustBlast. KBS Rust Converter is a good choice for completely rusted surfaces and will stop existing rust, but RustSeal will provide the longest-lasting protection when refinishing a rusty truck frame.
Frequently Asked Questions
| Can I use RustSeal directly over rust, or do I need to remove all of it first? RustSeal can be applied directly over treated rust to encapsulate and stop it, so you don't need to remove every bit of rust down to bare metal. Removing loose, flaky rust first and prepping with KBS Klean and RustBlast gives the best adhesion and longest-lasting results. |
| How long does KBS Rust Converter take to cure? KBS Rust Converter is dry to the touch in about 10 minutes and fully cures in about 24 hours. Thick coats may take a little longer, and a second coat can be applied after the first has dried for 24 hours. |
| Can I top coat KBS Rust Converter with a colored finish? Yes. Once Rust Converter is fully cured, it acts as an excellent primer for oil, acrylic, and epoxy-based paints, including BlackTop for a glossy black finish. |
| What's the main difference between RustSeal and Rust Converter? Rust Converter is a fast, low-labor aerosol that chemically converts rust into a paintable primer layer. RustSeal is a full rust-preventive coating system that forms a permanent, flexible, non-porous barrier and offers the longest-lasting protection, especially for frames that see hard off-road use. |