Rust Removal & Body Fillers

Hi. I have purchased the Rust Doctor to remove rust from my car hood. Not only is the hood rust covered, it needs body work. Is it okay to spread body plastic over it and/or will it hold up without any problems chemical or other wise?

Thank you,


That’s a great question Joe! You can apply body filler/putty on the Rust Doctor treated surface. Slightly scuff the surface with some 200 or 300 grit sand paper so you can get a “good bite” in the already treated Rust Doctor surface. You can apply virtually any product over a Rust Doctor treated surface, including fiberglass, bed liner and sound deadening coatings.

The Rust Doctor team had a real challenge when they decided to restore their own project – A 1969 Pontiac Bonneville Ambulance. Talk about rust removal! There was plenty of body work to be done as well, which included using body plastic. Then there was the painting, cleaning up chrome, and reclaiming the whole interior.

The ambulance had been used  at the Bonneville Salt Flat Time trials for several years in the early 70’s. The environmental conditions were rough and took its’ toll on the Bonneville. It was eventually was bought by a private party in Arizona and then the Rust Doctor team found it on Ebay and brought it home to Oregon. It was a “love of labor” as most car projects are. It took time to gather parts, prepare the ambulance for rust removal with Grease Doctor and then converting the rust permanently with Rust Doctor. It has now been restored to the beauty it once was. As many of you do, we named our car. She is now called “Bonne”. We take her to car shows, parades, and sometime take her to trade shows we attend. Maybe someday we will see Joe or some of our other customers in a show with their projects. Feel free to send us your success story and pictures. We would like to feature them on our blog. Just contact us at the Rust Doctor. Here are some pictures of the Rust Doctor 1969 Pontiac Bonneville Ambulance.

The Rust Doctor Team

in a show

This is the 1969 Pontiac Bonneville Ambulance before work is done.


Power washing under carriage of “Bonne” picture by Graham Lewis Fine Photography.

Car putty on back rear after rust removal.

Car putty on back rear after rust removal.


Bonne Side view of 69 before chrome

Here is an after shot of the same area. We decided to paint the majority of the ambulance red.

The interior of "Bonne". Hard to imagine such a small space for patients.

The interior of “Bonne”. Hard to imagine such a small space for patients.

This is Bonne in Reno's Hot August Nights cruise. Photo courtesy of Graham Lewis Photography.

This is Bonne in Reno’s Hot August Nights cruise. Photo courtesy of Graham Lewis Fine Photography.



Tips & Tricks for Those “Hard to Reach Places”

Our customer Tom inquired about using a Hudson garden sprayer to apply Rust Doctor to repair rust on his truck.

Thanks Tom, for your question on how to approach rust removal. You can apply Rust Doctor with a Hudson Sprayer or any type of garden sprayer on rusty metal. However, the sprayer does not atomize the paint very well because there isn’t enough pressure in the tank. Consequently you don’t get a nice even spray as you would with a spray gun with a latex tip (19-22) or with an airless spray gun. The Hudson Sprayer works great for places that are hard to reach on your rusty metal as you can use the long wand to reach down into the bottom of a door or areas on the undercarriage. Painting with a brush will give you a smoother surface on rusty metal. Here is a link to our “how to” page  to make your rusty metal project look great.

Here are more “TIPS & TRICKS” on how to repair rust on your projects.

 Rust Doctor is a very versatile product. Here are various ways you can use Rust Doctor to treat and seal rusty metal.

  •  One of the most difficult problems in treating rust is access to the rusted area. In car restoration, for example, inside doors it is difficult to get at seams and welds that contain rust. One solution is to use a spray bottle to squirt Rust Doctor into hard to get at places. By setting the spray adjustment to a stream, you can direct Rust Doctor at the elusive welds and seams. Follow-up by using a spray gun to spray the remainder of the inside of the door to completely stop any rust that is present and seal the metal.
  •  Another method for getting at difficult places is to use a syringe to squirt Rust Doctor into tight locations where you need more control that the spray bottle provides. The syringe will shoot a stream of Rust Doctor into a tight location. You can easily control the force and quantity of the spray by varying how hard you push on the plunger.
  •  To clean large areas of rusty metal, pressure washing will effectively remove dirt, rust, grease and loose paint in one operation. For storage tanks, car frames and bodies, metal structures and etc., high pressure washing will effectively prepare the surface for Rust Doctor treatment. If grease is present, add a cleaner/degreaser such as Grease Doctor to the wash water. Be sure to rinse the surface before moving on to the next step of using the Rust Doctor.
  •  Before you treat metal with Rust Doctor, you must remove any grease or oil that might be present on the rusted surface. On very old metal, oil down in the rust is difficult to see. One way to check for oil or grease in the rust is to spray the surface with a fine mist of water. If oil is present, the mist will lay on the surface. Without the presence of oil in the rust, the mist will soak into the rust, indicating that you will not need to worry about a cleaner/degreaser. Try several areas to be sure oil or grease in not present. The Grease Doctor is a very effective cleaner/degreaser. Since it is a concentrate, you can decide how many parts of water to Grease Doctor parts you would need.
  •  When treating metal with Rust Doctor, it is important to force Rust Doctor into places where metal is welded or riveted. Rust builds up where the two pieces of metal are attached. Foam brushes work very effectively at forcing the paint between the metal pieces. Even if you can’t force Rust Doctor completely between the metal, it will create a barrier along the outside edges to keep moisture and oxygen from reaching whatever rust could not be treated. This is important because the rust will continue to grow if it is not sealed off. If the surface is painted, rust stains will appear along the edges of the seam where the metal is connected if that connection is not sealed off.
  • On automobile bodies, it is important to treat the front and back of metal body panels. If you only treat the front of a panel and then paint it, rust will migrate around the edges from the back side of the panel and stain the paint or create bubbles that eventually cause the paint to release. In some cases additional panels cover the backside of body panels, making it difficult to treat rust. It may be necessary to drill holes in these covering panels (this is inside the body and not visible) and spray Rust Doctor between the panels to stop the rust. This is the only way this rust can be stopped. The holes can then be welded or filled with rubber plugs.
  • Clean-up is a snap with our Rust Doctor products. Many of our competitors rust products require using solvents to clean tools such as  brushes and sprayers. The water clean up of our products is not only a time saver when working on your rust repair, it is also much safer.  Rust Doctor is non-toxic, non-flammable and biodegradable.

question-mark  samll

Remember, if you have any questions about how to stop rust, don’t hesitate to call or email us. The Rust Doctor team will help you with your rust repair questions.


A garden sprayer like this can be your best friend when trying to reach those hard to reach area on your rusty metal project.

How Much Rust Doctor Do I Need?

We often get questions about how much Rust Doctor is needed to repair rust. Here is a typical question we get. If you have a rusty metal question about usage, don’t hesitate to call or email us. We have helped our Rust Doctor customers figure square footage on some pretty interesting projects, like rusted roofs, iron picket fences etc.

Question About Rusting

I have an all original 1964 pick up that is rusting.

I want to keep it for my sons, but I’m afraid that the rust will get the better of it before they do.  If I use the Rust Doctor  product to stop the rust today, will my boys have any issues in the future  with sanding, priming, and painting?

This would be in about 8 – 10 years.



Thanks for your question Bruce. Sounds like your boys will have a great truck to work on in the future. It’s wise that you are thinking about fixing the rust now.

Once Rust Doctor turns the rust to a black iron oxide, the rust is permanently gone. If you apply Rust Doctor to your truck and want to work on it any time in the future (years later if need be), all you will have to do is slightly scuff the surface with fine sandpaper before you begin priming and painting. The clear primer left on the surface after Rust Doctor is applied gets harder over time. Scuffing is not necessary within the first 30 days of application. One way to avoid having to sand the surface in the future is to apply a primer within 30 days of the original Rust Doctor application. This way you (or your sons) will not need to sand it before they choose their favorite color to paint that ’64 truck.

Typically, a quart of Rust Doctor will cover all the floor boards and trunk area of a car or the frame of a car or truck . If you need to do more than a frame, you will need at least two quarts. Each Rust Doctor quart will cover 50 square feet of rusty metal. The gallon will cover 200 hundred square feet which is your whole truck. Here one more resource from our Rust Doctor web page.

The Rust Doctor Team

No one wants to see an old truck or car end up in the "rust graveyard" Repair rust now.

No one wants to see an old truck or car end up in the “rust graveyard” Repair rust now.















A Sears Mail Order Car

Imagine the love and elbow grease that was needed to remove rust from this1909 Sears Motor Buggy Model K. The Rust Doctor travels to several car and agricultural shows every year. While in Washington State, Wayne showed up at the Rust Doctor booth to tell us how much he liked using  the Rust Doctor products to remove rust from his project. A member of the Rust Doctor team went over to see Wayne’s amazing project. It was a beauty! This was an amazing mail-order motor buggy that originally sold in the Sears catalog for $395. We recently contacted Wayne for a “before” picture of his project. We couldn’t believe the magic he had done with his buggy! Thanks to Wayne for sharing his “before ” picture of his project. Look and see how Rust Doctor can work to remove rust without grinding or sandblasting.


The Sears Motor Buggy before rust removal

The Sears Motor Buggy before rust removal

Motor Buggy - Rust removal a success!

A Rust removal a success!


If you are working on a a rusty metal project and using  Rust Doctor products, feel free to upload us some pictures of how it is going. We enjoy sharing your success. It can be cars, a metal fence, a oil tank children’s toys etc. Just email us with your pictures and tell us about your story.


You Can Be a Rust Artist

The Rust Doctor thought you might like to see a new type of “art” show. While we may not be as famous as some of the old master painters, we are great at what we do! We want to share our “masterpiece” pictures on how to remove rust. Do you want to become a master painter too? It just takes a few tools, a little time and Rust Doctor products and you can create a finished masterpiece – FREE of rust. Take a peek. Let the artist in you out!

how to use- sm brush

Apply Grease Doctor, let it rest for a few minutes and then brush off . You may want to use a pressure washer for larger projects. This dissolves contaminates and releases them from the surface.

how to use small apply RD

After your rusty metal has dried, apply the rust doctor.

3 part panel -small

Here is a shot of a before, during process and what the finished panel look like. This is a 1942 Dodge floorboard piece.

restored metal -small

Fully converted rust metal that is now converted to magnetite. This is another part of the Dodge floorboard.

finshed piece - small

Finished piece of rusty metal. You have stopped the rust. Your tools were simple, a wire brush, brush, a little elbow grease, and Rust Doctor products.

how to use 003

Water clean up!


Want more information how how to use Rust Doctor products to repair rust? Check out our video on our home page.