Guide 03 · Bodywork
Fix wheel-arch rust before it spreads
Surface rust and small bubbles are DIY-fixable if you grind to clean metal; rust that's eaten through needs a patch panel or a pro.
Hard A full weekend Messy, but very satisfying
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Tools I used
| Tool | Why you need it | Link |
|---|---|---|
| Angle grinder + 80-grit flap discs | Takes rust back to bare metal fast | Check price → |
| Wire wheel attachment | Cleans pits and tight curves | Check price → |
| Rust converter | Neutralizes rust left in pits | Check price → |
| Epoxy primer | Seals bare metal so rust can't return | Check price → |
| Body filler + spreaders | Rebuilds the shape | Check price → |
| Sanding block + 80/180/320 paper | Shapes and smooths the filler | Check price → |
| Seam sealer | Seals the arch lip from water | Check price → |
| Safety glasses, respirator, gloves | Grinding throws sparks and dust | Check price → |
Shop the whole kit
8 tools, one click, straight into your Amazon cart.
Add all 8 to cart →8 tools, one click, straight into your Amazon cart.
Steps
- Mask a wide area. Remove the wheel for easy access to the arch lip.
- Grind every bubble back to shiny metal, going 2–3 cm past the visible rust.
- Poke the metal. If a screwdriver goes through, stop here and plan a patch panel.
- Wire-brush the pits, then apply rust converter and let it cure.
- Spray epoxy primer over all bare metal. Let it cure fully.
- Apply thin layers of body filler. Shape with 80 grit, then smooth with 180.
- Seam-seal the inner lip of the arch.
- Prime, wet sand with 320, then base coat and clear to match.
Pro tips
- Rust you can see is always smaller than the rust you can't. Keep grinding until it's clean.
- Never put filler straight on bare or rusty metal. Primer first, always.
- Rinse salt out of your arches every spring. Road salt is brutal on wheel lips.
Find a pro near you
When to call a pro
Holes through the metal, rust on structural parts (rocker panels, frame rails, strut towers), or anything on a car you're about to safety-inspect.
Rather not DIY it? Tell us where you are and local shops will send you a quote.