Rust Removal/Paint

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If youre gunna use por15 the metal has to be ridiculously clean or it won't stick. Ask me how I know lol. Also the sun will ruin it. Type "por15 sucks" in google and u will see how many people have had issues with it not sticking if it isn't prepped perfectly. I use master series and it came out great and never had any problems. The silver primer first then the black topcoat. It goes on with foam brushes.
 
I've been using POR15 for years and in real world usage it has been flawless. I'm guessing the failures are due to improper prep and application. Here's my process:

1. Sandblast. Even if this means standing in the driveway and blasting an entire frame.
2. Use POR15 Marine Clean exactly as recommended and rinse very well with water.
3. Immediately use POR15 Metal Ready or whatever it's called these days. (Phosphoric acid treatment.) Follow the instructions - keep the workpiece continually wet for 15-20 minutes. Immediately rinse very very thoroughly with fresh water. If you don't rinse well enough there will be a powder residue that will inhibit adhesion.
4. Let the work piece dry dry dry - for days if necessary. Must be bone dry.
5. Apply 2 coats of POR15 and then 1 coat of POR15 TopCoat (may have changed the name) all in the same day. As soon as the stuff gets tacky apply the next coat. The TopCoat has UV protection so solves the chalking issue with the regular POR15 paint. Yes I do this on underbody stuff as well - just to be consistent. My oil pan should never see sunlight but nevertheless it has TopCoat on it.

This is a lot of work, and a lot of money but it's as permanent as such things can get.

Eric
 
POR15 is ~$50 a quart at my ripoff paint store. Hammerite is $13 quart at Home Depot. I have used Hammerite on nasty rusty junk (log splitters, trailer floors, truck frames) for years with great success. UV stable right out of the can.
 
POR15 is ~$50 a quart at my ripoff paint store. Hammerite is $13 quart at Home Depot. I have used Hammerite on nasty rusty junk (log splitters, trailer floors, truck frames) for years with great success. UV stable right out of the can.
Can you coat over a little existing rust? I dont have the time or the means to do a frame off coating and can see rust building up on the axles and what not
 
Yes - most of these products are designed to go over light/moderate rust. Big flaky rust would not work, but they adhere to surface rust well.
 
You can pick up a big bottle of ospho for like $15 at true value. Put it in a squirt bottle and spray over the rust. Wash it down the next day and use whatever you choose on the chassis. I Used it under master series on an old vw bug frame/floor pans and used it on my fj62 before paint and the rust hasn't come through in the 2 years since it got painted.
 
I brushed mine on. Also hardly any prep just scraped the big chunks of rust off. 3 years still on there. Plus i live on the coast
 

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