How to Touch up Rust Spots on Powdercoated Iron Railing

Sometimes powdercoated rails develop blisters or scratches that allow moisture to penetrate between the powdercoating and the bare steel beneath which causes rust spots to appear. Fix the problem when it is small and it will not become a big and expensive repair.This article will describe how to touch up rust spots on iron railing.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• sandpaper medium 150 grit
• sandpaper fine 200 grit or emery cloth
• clean wire brush
• 2" painter's tape
• clean rags
• mineral spirits
• rust inhibiting primer spray
• rust inhibiting spray paint to match rail color
• clear coat spray paint satin or gloss depending on the luster of the railing

1. Thoroughly inspect every part of your railing. Pay particular attention to weld joints at the top and bottom of each picket, as well as the area under the cap rails between the cap rail and the railing frame.

2. With a small, clean wire brush, brush away any loose rust. Take care not to scratch or damage surrounding powdercoat finish.

3. Using 150 grit medium sandpaper, sand affected rust area down to bare metal. Feather your strokes at the edges so that when painted, the repair will "disappear" and blend properly with the surrounding powdercoated finish.

4. Using 200 grit sandpaper or an emory cloth, fine sand the bare metal to rub out any scratch marks on the metal. Remember to feather your strokes gently so that the repair will blend with the surrounding area.

5. Lightly dampen a clean rag with mineral spirits and use this to clean any residual dirt and dust from the area to be painted. Allow to dry thoroughly before proceeding to the next step. Wipe the surrounding rails with Mineral Spirits to obtain an accurate gauge of the luster of your existing finish.

6. Mask off the area to be painted with painter's tape. Cover surrounding area with newspaper or tarp to prevent overspray spots. Be sure to leave feathered areas exposed.

7. Lightly spray rust inhibiting primer onto bare metal. Allow to dry thoroughly. Apply a second coat and allow that to dry completely.

8. While the primer is drying, check the lustre of the surrounding rails. Powdercoating dulls over time with exposure to the elements. Satin or flat paints are usually the best choices for your top coats.

9. When primer coats are completely dry, take the emory cloth and lightly feather the edges so that you will achieve a smooth finish.

10. Remove painter's tape

11. Apply the first coat of rust inhibiting spray paint that matches the color and lustre of your rails. CAUTION: DO NOT USE A BRUSH TO APPLY PAINT. Allow paint to dry thoroughly. Apply second coat of paint and allow it to dry overnight.

12. Apply a protective coat of clear coat matte, satin or gloss spray. Allow to dry thoroughly.
    
    You're DONE, and your investment in your rails is now protected from further damage.

Tips & Warnings

• NOTE: To prevent having to go through this exercise in the future, make it a policy to inspect your railing the first and last mowing of the season and you can just wipe any small rust "dots" with a soft cloth and hit them with a small spray of matching paint and you're done. We have found that doing this one thing prevents a small task from becoming an overwhelming one.
• Do not neglect your rails. They are expensive to replace or have removed, sandblasted and re-powdercoated. A little preventive maintenance twice a year can protect your investment and add value to your home. It can also save you from the expense of having to hire a professional iron fabricator to repair or fabricate new sections for your railing.

Resources

• Rustoleum website
• The Rust Store

[jdswhmsi]

on 8/17/2009 Thanks for commenting. I know it's a tough job to restore rails to their best appearance but it is worth the effort.

[dduvall]

on 7/28/2009 Well written and very informative