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post #14 of (permalink) Old 25th April 2009
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I can't advise you what to do, only you will know your own competence and what standards you are willing to accept.

However, here's what I would do;

1. Jack up rear of car & remove wheel, leaving car secured on axle stand.
2 Using orbital sander & 80 or 120-grit sanding discs, remove all traces of rust on the inside & outside of the wheelarch.
3. Go over the same areas with 320-grit discs to get a feathered edge and a smoother surface).
4. Apply Kurust to the surface which will eliminate any rust spots pitted in the surface.
5. Apply a few (3-4) light coats of primer - allow to dry, and very lightly rub down with 800-grit wet & dry paper.
6. Apply (4-5) coats of basecoat (start light, but get progressively heavier with each successive coat). Again, allow to dry.
7. If your car has a pearlescent finish, you will need to add lacquer, if not - leave it for a week, and then lightly cut-back with 'T'-cut, then lightly polish.

Don't use masking tape as you don't want a 'stepped' finish.

To finish it off, apply underseal/hammerite to the inside edge of the wheelarch - this will give extra protection where its needed.

You are realistically looking at 2 days work if you are working outside, half that if you can enjoy the luxury of working indoors.

Cost of materials (circa 40-50).

Be under no illusion, its a bigger job than it looks.

Hope that helps,


This job should never be complete - the day I think I've done it all, is the day I resign.

S.M.A.R.T. Technician
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