I'm Pissed At My Car!

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I had the same issue with my housing so I had it sand blasted and powder coated.
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jae said:
Ok, you're saying the paint is sanding off but the rust is not. Even a wire wheel is not getting the rust off. May I ask the "grade" of the wire wheel, is it soft, medium, hard / aggressively stiff? If you're using a very soft bristle it's not going to get any heavy rust off, you will have to get a a heavier grade and lots of elbow grease.

Else blast.

Yes this is exactly what I'm saying. I was using a very agressive wire wheel. I'm not so much worried about the paint, I'm worried about the giant, stuck-on chunks of rust underneath the paint. Today I tried using a 45 grit mini sanding disc on the end of a drill, and it did a much better job than the wire wheel. It was a PIA, but at least it was working. I think I am going to sand all the rust chunks off, however long that will take me, and then coat the entire axle in 30W oil to keep it from rusting again. I dont want to spray paint it. I've come to hate spray paint. It's messy, not durable, and a shiny new rear axle would look out of place within the midst of my surface rust covered undercarriage. I always end up getting overspray on something, no matter how well I tape off (not that the idea of taping off everything in the undercarriage appeals to me, or anything), and within a month of driving, it'll look like sh*t because it'll be all stone- chipped.
 
I used an angle grinder with a medium duty wire wheel, maybe try a heavy duty one on the rough parts. You might need to spray the housing down with some aircraft paint stripper to remove the rustoleum. I actually painted mine with a brush using rustoleum industrial enamel because i'm too cheap for por 15, looked great after 2-3 coats. Oh, and use eye protection whenever using those wire wheels, I had one close call with one of those, considered myself lucky and always wear goggles now.
 
I'm gonna attempt to make a trip to the auto parts store today to buy some more of those mini sanding discs. They seemed to work miracles compared to the aggressive wire wheel I was using. While I'm there I'll also try to get some 30w oil to paint it with. The discs leave a couple scratch marks, but I'm not worried about scratch marks, I'm worried about rust. Nothing bothers me more than when someone takes something shitty, covers it in paint, and then tries to pass it off as something brand- new. Then I have my dad rooting for the previous owner saying "oh it looks fine, don't waste all your time doing that." Oh, well.
 
If it's chunks of rust, did you try a hammer and a chisel? I had to do that with my bumper shells. Huge flakes of rust on the back side. You would basically be hammering and breaking off the un-saveable metal instead of having to sand all the way through it.
 
Once you get it cleaned up to your satisfaction why don't you just POR15 it when you are done to protect it from rusting any further and later on if you want to really detail it pull the rear end and get it sand blasted.
 
565bbchevy said:
Once you get it cleaned up to your satisfaction why don't you just POR15 it when you are done to protect it from rusting any further and later on if you want to really detail it pull the rear end and get it sand blasted.
x2
If you brush enough coats of it on, I'd imagine it working just as well if not better than 30 weight oil in the long run. I know you're worried about rock chips, but personally I'd feel better with a couple rock chips on a painted rear rather than a rusty rear slathered in oil.
 
307 Regal said:
If it's chunks of rust, did you try a hammer and a chisel? I had to do that with my bumper shells. Huge flakes of rust on the back side. You would basically be hammering and breaking off the un-saveable metal instead of having to sand all the way through it.

I was able to do this to some avail for the really large chunks of rust. However most of the smaller chunks of rust which are the main problem, are embedded in the thick paint, so you can't chisel them off. I'll post a picture later today so you can see what it looks like.
 
565bbchevy said:
Once you get it cleaned up to your satisfaction why don't you just POR15 it when you are done to protect it from rusting any further and later on if you want to really detail it pull the rear end and get it sand blasted.

I'll consider doing it. I just feel like I'm slopping paint on everything. By the time it's all said and done, it'll take about a quart, so there's $25 gone. I, my parents, my car buddies, have always used 30W oil as undercoat, and I know for a fact it works great through a PA winter. And it's a lot easier to get off than POR 15 in case you ever have to re-do the axle while it's still on the car.
 
The wire wheel I was using, along with the mono sanding discs I'm now using-

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The torquey, million- year old craftsman drill I've been using-

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A few pics of the axle in all it's rustoleum- covered, non- posi glory-

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