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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

ToolWhy you need itLink
Angle grinder + 80-grit flap discsTakes rust back to bare metal fastCheck price →
Wire wheel attachmentCleans pits and tight curvesCheck price →
Rust converterNeutralizes rust left in pitsCheck price →
Epoxy primerSeals bare metal so rust can't returnCheck price →
Body filler + spreadersRebuilds the shapeCheck price →
Sanding block + 80/180/320 paperShapes and smooths the fillerCheck price →
Seam sealerSeals the arch lip from waterCheck price →
Safety glasses, respirator, glovesGrinding throws sparks and dustCheck price →
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Steps

  1. Mask a wide area. Remove the wheel for easy access to the arch lip.
  2. Grind every bubble back to shiny metal, going 2–3 cm past the visible rust.
  3. Poke the metal. If a screwdriver goes through, stop here and plan a patch panel.
  4. Wire-brush the pits, then apply rust converter and let it cure.
  5. Spray epoxy primer over all bare metal. Let it cure fully.
  6. Apply thin layers of body filler. Shape with 80 grit, then smooth with 180.
  7. Seam-seal the inner lip of the arch.
  8. 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.