How do I stop my truck from rusting?

Keep the truck clean, protected, and maintained to slow or prevent rust. The quickest path is consistent prevention, plus prompt treatment of any spots that appear.

Rust is a common issue for trucks, especially in areas with winter road salt, coastal humidity, or frequent exposure to moisture and chips. This article explains why rust happens, practical steps you can take at home, and when to seek professional help for more extensive corrosion.

Why rust forms on trucks and how it spreads

Rust occurs when iron or steel reacts with oxygen in the presence of water or moisture. Road salt accelerates the process by increasing the conductivity of water and creating an electrolyte in which rust can develop more rapidly. Trims, seams, wheel wells, and undercarriage components are particularly vulnerable because they are exposed to salt spray, stones, and road debris. Chips in paint and protective coatings expose bare metal to the elements, giving rust a foothold that can progress if not addressed promptly.

Preventive maintenance you can do at home

Implementing a routine regimen is the most effective way to curb rust before it starts or to slow its spread. The following steps form a practical baseline for responsible ownership.

• Regular washing, with extra attention to the undercarriage, wheel wells, and pinch welds where salt and moisture collect.


• Drying thoroughly after washes or exposure to rain, and using a light, wax-based protective spray on exposed metal.


• Applying an underbody rust-preventive coating or sealant on vulnerable areas, ideally before rust appears.


• Touch-up paint and chip repair on exposed metal, especially along you paint edges and around trim gaps.


• Using protective bed liners and mud flaps to minimize stone chips and abrasion that expose metal.


• Seasonal checks for seals, drain holes, and gaps that could trap moisture, and addressing any leaks promptly.

Regular washing and protective coatings reduce moisture retention, slow corrosion, and create a barrier against salt and debris that can accelerate rust.

What to do if you spot rust

Early intervention can stop rust from becoming structural or costly to repair. The following steps are practical for minor to moderate surface rust, but seek professional help if you notice deep pitting, bubbling paint, or rust on structural components.

1. Assess the extent of the rust to determine whether it’s superficial or penetrating, and check nearby structural members for integrity.


2. Clean the area with soap, water, and a brush, then dry completely.


3. Remove loose rust with a wire brush, sanding, or a rotary tool to create a stable surface for treatment.


4. Apply a rust converter or rust reformer (phosphoric acid-based products) to neutralize active rust and convert it into a paintable layer.


5. Prime the treated area with an epoxy or rust-inhibitive primer, then topcoat with matching automotive paint or a protective coating.


6. Seal seams and joints with an appropriate seam sealer to prevent water intrusion.


7. Reassess after a few months and reapply protective coatings as needed to maintain coverage.

If the rust is extensive or has reached the frame, floors, or critical load-bearing parts, professional assessment is essential. Structural rust can compromise safety and resale value, and DIY repairs may not suffice.

Professional options for severe rust

When rust is extensive or structurally compromising, professionals can provide more comprehensive solutions. Here are common routes used by shops and manufacturers.

• Thorough undercarriage inspection, rust removal, and application of high-performance rust prevention coatings or coatings with zinc-rich primers.


• Sandblasting or grinding to remove deep corrosion, followed by epoxy primer, sealant, and factory-quality topcoats.


• Frame repair or reinforcement, including stitching, plating, or replacing severely corroded sections, to restore structural integrity.


• Professional undercoating services, including lifetime or multi-year warranties on certain coatings, tailored to driving conditions and climate.

Choosing a shop with experience in automotive corrosion repairs can save money in the long run by extending the life of your truck and preserving safety and resale value.

Tips for choosing a shop and planning costs

Ask about the extent of their rust evaluation, the materials they use (zinc-rich primers, epoxy primers, and high-quality topcoats), warranty coverage, and whether they offer undercoating options. Costs vary based on the rust's severity, the vehicle’s size, and the required repairs, but investing in robust prevention and timely repairs often pays off in longevity.

Summary

Rust is preventable and manageable with a combination of regular cleaning, targeted protective coatings, and prompt treatment of any spots that appear. For minor rust, DIY methods like rust converters and primer can be effective; for serious or structural rust, professional evaluation and repair are essential to ensure safety and durability. A proactive approach—coupled with periodic inspections and protective measures—can keep a truck looking good and performing reliably for years to come.

Can rust on a truck be fixed?

Yes, you can fix rust on a truck, but the extent of the repair depends on the severity and location of the rust. Surface rust can be repaired at home by sanding the area to bare metal, applying a primer, and painting it, while more severe rust, especially on structural parts, may require professional help or even replacing the damaged section. For a proper and long-lasting repair, you'll need to remove all the rust, treat the metal, fill any holes, and then repaint and protect the area.
 
Steps to fix surface rust

• Remove the rust: Sand the area with coarse sandpaper to expose the bare metal, removing all traces of rust and peeling paint. 
• Clean the area: Thoroughly clean the area to remove all dust and debris. A solvent cleaner can be used for final preparation. 
• Apply a rust inhibitor: Use a rust converter or a rust-inhibiting primer to treat any remaining rust and protect the bare metal from future corrosion. 
• Apply filler (if needed): For deeper pits or holes, apply an automotive body filler and sand it smooth once it dries. 
• Paint the area: Apply a primer followed by a few coats of matching automotive paint. Finish with a clear coat to protect the new paint. 
• Wax and protect: After the paint has cured, wash and wax the area, and consider applying a rust-proof spray for added protection. 

This video demonstrates how to repair rust holes on a car without welding: 58sClassic Car MaintenanceYouTube · Oct 4, 2024
When to seek professional help

• Structural rust: If the rust is on structural components like the frame, cab mounts, or pinch rails, it's often best to consult a professional body shop. These areas are critical for vehicle safety, and DIY repairs may not be sufficient or safe. 
• Extensive rust: If the rust is widespread or has created large, deep holes, it may be more effective and safer to have a professional perform the repair or replace the part entirely. 

Tips for a lasting repair

• Clean regularly: Frequently wash your truck, especially after driving on salty roads, to remove corrosive elements. 
• Fix chips immediately: Don't let small paint chips or scratches go unaddressed, as they can quickly lead to rust. 
• Consider prevention: After fixing the rust, use protective coatings like wax and rust-proof sprays to help prevent future corrosion. 

This video shows how to repair rust with basic tools and without welding: 1mPaint SocietyYouTube · Apr 7, 2022

What permanently stops rust?

To stop rust permanently, you must first remove existing rust and then apply a permanent protective barrier to the clean metal surface. Methods include cleaning to bare metal and applying a protective coating like an epoxy primer, or using a specific rust-inhibiting coating like POR-15, followed by maintenance and environmental protection. 
This video demonstrates how to remove rust and apply a protective coating: 1mJay Leno's GarageYouTube · Dec 20, 2014
Step 1: Remove existing rust

• Sand or sandblast: Thoroughly remove all visible rust from the surface, ideally down to bare metal. 
• Use rust removers: For severe cases, a chemical rust remover can be used. Follow the product's instructions for application and neutralization, as the acid residue must be removed before painting. 
• Clean the surface: After sanding or using a chemical remover, thoroughly degrease and clean the surface to remove any debris or chemical residue. 

This video shows how to prepare a surface for rust prevention: 48sPaint SocietyYouTube · Feb 5, 2022
Step 2: Apply a permanent protective barrier

• Apply an epoxy primer: Once the metal is clean and dry, apply a high-performance epoxy primer. This creates a strong, direct bond to the metal, offering excellent rust protection and a solid base for a top coat. 
• Use a dedicated anti-rust coating: Apply a high-performance, non-porous coating designed to go directly over prepped rust, such as POR-15. These coatings seal the surface from moisture and air. 
• Powder coat: For a very durable finish, have the part professionally powder coated. This involves applying a dry powder that is then heat-cured to form a protective layer. 
• Galvanize: For new steel parts or if you are willing to have the part stripped and dipped, galvanization (coating with zinc) provides permanent, long-term protection. 

This video shows how to apply a rust prevention coating to a car frame: 55sClassic Truck PerformanceYouTube · Sep 21, 2022
Step 3: Maintain and protect the environment 

• Minimize exposure to moisture: Keep the object in a dry environment. Even small amounts of moisture in the air can cause rust over time. 
• Regularly clean: Keep the surface clean to prevent the buildup of dirt and salt, which can trap moisture and accelerate corrosion. 
• Apply additional protection: Periodically apply a rust inhibitor, wax, or oil to the surface to add an extra layer of defense against the elements. 

You can watch this video to learn about applying rust prevention wax to a car: 1mGuzzi Fabrication - D.I.Y Auto RestorationYouTube · Mar 6, 2025

How to stop a truck from rusting?

And the body of this truck. This is all stuff that I've had and I've been using for years now i have fluid film which is like a waxy oil type of coating. So it sticks on pretty well.

Can I put WD-40 on metal to prevent rust?

Yes, WD-40 protects metal from rust and corrosion by creating a barrier that displaces moisture. While the original formula provides a temporary, short-term protective film, the WD-40 Specialist Corrosion Inhibitor is specifically designed for long-term rust prevention, blocking rust for up to one year outdoors or two years indoors. 
You can watch this video to learn how WD-40 works for rust protection: 34sWD-40 Australia & New ZealandYouTube · Apr 27, 2018
Original WD-40 Multi-Use Product 

• How it works: It protects metal from rust and corrosion by displacing moisture. 
• Best for: Temporary, short-term protection, like after cleaning a tool. 
• Limitations: The protection it offers is temporary and not as long-lasting as dedicated rust inhibitors. 

WD-40 Specialist Corrosion Inhibitor

• How it works: This product provides a long-lasting, non-drying protective film that blocks rust and corrosion. 
• Best for: Long-term storage, extreme environments, and preventative maintenance where metal parts will be exposed to the elements. 
• Protection period: Up to one year outdoors or two years indoors. 

Other related products

• WD-40 Specialist Penetrant: Excellent for freeing rusted and seized parts. 
• WD-40 Specialist Gel Lube: Offers a thick, long-lasting gel coating for enhanced protection on various surfaces.