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

Cutting Out Rust And Replacing It With Fresh Steel Is The Way To Repair Minor Body-Panel Rust
By Miles Cook
Photography by Miles Cook
Rust Removal Rust
Our Highland Green '69 Mustang... 
   
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Rust Removal Rust
Our Highland Green '69 Mustang project car has relatively decent paint on it. That said, there are some minor rust issues-the most obvious is at the lower right corner of the driver-side taillight.
Rust Removal No Rust
After final color sanding... 
   
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Rust Removal No Rust
After final color sanding and buffing by the crew at Crook Brothers and reinstallation of the taillights, we have a perfect and undetectable repair.
Rust Removal Rust Cancer
After removing the taillight,... 
   
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Rust Removal Rust Cancer
After removing the taillight, it was clear the rust in this area resembled a cancer. The rest of the taillight panel was in good condition, so getting to this immediately was better than later-or never.
Rust Removal Rust Removed
When we first discussed the... 
   
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Rust Removal Rust Removed
When we first discussed the repair with the Crook brothers, one consideration was replacing the entire taillight panel, which was deemed unnecessary due to the minimal amount of rust. The decision was to cut out the rust and replace it with a small piece from a new panel. We began by cutting out the rusty area with a cutoff wheel.
Rust Removal Sand Paint
Next we sanded the paint with... 
   
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Rust Removal Sand Paint
Next we sanded the paint with a sanding wheel to securely weld the new piece. The opening created by cutting out the rusty portion of the panel is clearly visible.

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