How to Repair a Rusty Nerf Bar on a Truck
After years of protecting your truck while you take it off road the nerf bars, or step bars, are getting rusty. Not only is the rust unsightly but if it gets too bad it also can weaken the nerf bars so they don't have the strength to protect your truck anymore. The rust is easily taken care of, however, and you will be out on the trail again in no time.
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Things You'll Need
- Naval jelly/rust dissolver
- Socket set
- Tarp
- Wire brushes
- Emery cloth
- Steel wool
- Baking soda
- Old paintbrush
- Drill with wire-brush attachment
- Rags
- Safety glasses
- Rubber gloves
- Metal paint with rust inhibitors
Instructions
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Remove and Prepare the Nerf Bars
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1
Take the nerf bars off the truck and set them on the tarp. This will make cleanup easier later. Put the bolts that hold the bars on in a cup so they don't roll away.
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2
Knock as much of the loose rust off with the back of the wire brush.
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3
Use the brush to remove the rust that will come off easily.
Removing the Rust
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4
Put on the safety glasses and gloves.
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5
Using the paintbrush or rags to cover the rusty areas of the nerf bar with the naval jelly.
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6
Use the steel wool or wire brush to scrub the rust off.
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7
Put the baking soda on the naval jelly after it has dissolved the rust--that will neutralize the remaining phosphoric acid in the naval jelly.
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8
Rinse off the neutralized naval jelly and dry the nerf bars.
Repainting the Nerf Bars
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9
Use the emery cloth and wire brushes to smooth out any rough spots and remove any small bits of rust that might remain.
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10
Spray paint the nerf bars. Do one side of each bar at a time and let that side dry before doing the next to eliminate smudging from where the bars were in contact with the ground.
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11
Apply second and third coats the same way to get a durable finish that will protect your investment.
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1
Tips & Warnings
Work in a well-ventilated area to minimize the chance of inhaling the fumes from the naval jelly or the spray paint.
If you have a way to suspend the bars for painting from a ceiling joist in a garage, the painting will go much faster since you don't have to wait for one side to dry before painting the other.
If the rust isn't too thick, you can use a rust-fixative primer, which neutralizes the rust to stop its spread and primes the surface for a better finish.
Naval jelly is made with phosphoric acid in concentrations up to 70 percent and up to 1 percent sulfuric acid.
