Ford Mustang Rust Removal - How To Remove Body-Panel Rust

After smoothing with the small bit, followed by additional work with a metal brush wheel, the area was ready for a small amount of filler material. Also visible is an area between the two right-hand taillights where another piece of new steel from the donor taillight panel was cut out and installed. The same processes for the corner of the taillight area were used in this part of the panel.

A small amount of All-Metal material was applied, shown dried but yet to be smoothed. All-Metal is different than regular body filler. It repairs metal with metal and is more advanced than a typical body-filler material because it's pliable.

Once the All-Metal dried, it was sanded. The panel was final-shaped and prepared for primer.

With the area taped off, the panel was treated to a clean and even coat of primer. After the primer was applied, we waited overnight for it to dry and set.

After 18-24 hours, the primer was completely dry. The area was wet-sanded with 1,000-grit sandpaper, followed by 1,500-grit, getting it completely smooth and free of surface imperfections.

After wet sanding, the car was taped for the paint and clearcoat application process. Robert Matheson was done in about two hours. After allowing the area to bake in the booth for 45 minutes, the surface sat overnight allowing the base/ clear paint job to thoroughly dry and set up before color sanding and buffing.

The next day, the area was color-sanded with 1,000- and 1,500-grit wet sand paper.

Next, the area was buffed and polished with rubbing compound and a soft cloth buffing wheel.

With the body and paint work complete, the taillights and quarter-panel extension caps were reinstalled to show how well the project turned out.