Repair Rust With Epoxy

Rust is a term given to the process of oxidation.

Rust is a term given to the process of oxidation. It is a natural reaction that occurs between iron and oxygen in the presence of water or humidity. Unfortunately, given enough time, most any metal surface will rust unless it has been treated with a galvanizing process or the right type of paint. Once it has set in, you must remove the oxidation and coat the surface with the proper sealant to prevent a return of the problem. Epoxy is a good choice to seal out rust when combined with a spray rust sealer, however, you must work meticulously to remove all of the rust before you apply any type of coating. Does this Spark an idea?


1. Scrape the rust loose from the surface using a wire brush.

2. Sand away any remaining small particles of rust using 80-grit sandpaper.

3. Protect any areas you don’t want coated with epoxy by covering them with painter’s tape.

4. Apply a coat of spray rust sealer to the area you want to protect. Allow the sealer to dry for four full hours.

5. Pour the epoxy resin into the 2-gallon painter’s pot. Stir in the catalyst using a wooden stir stick.

6. Apply the epoxy to the surface using a 2- to 4-inch latex paintbrush. Allow the epoxy to dry and cure for three full hours.