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Frequently Asked Questions

For Automotive Applications

 

 

What is the difference between Rust Bullet® Standard formula (Gold Label) and Rust Bullet® Automotive formula (Silver Label)?
Should I apply Rust Bullet only where rust is apparent?
Can I apply Rust Bullet Automotive with a brush?
How do I apply Rust Bullet Automotive with HVLP Spray Equipment?
Why do I need to apply multiple coats of Rust Bullet?
When do I apply the next coat of Rust Bullet or Rust Bullet BlackShell®?
Can Rust Bullet be used as a primer?
Is Rust Bullet compatible with automotive Fillers, Fiberglass, and Primers?
Can a surface coated with Rust Bullet be Welded?
What should I do if I waited too long before applying my next coat of a Rust Bullet
What steps are required when applying a Topcoat over Rust Bullet?
What is necessary prior to applying Body Paint?
Is Rust Bullet appropriate for undercoating my vehicle?
Is Rust Bullet recommended for use on Gasoline Tanks?
Is Rust Bullet recommended for use on an Exhaust System?
Can I apply Rust Bullet coatings under a Truck Bed Liner?
What are the effects of Fuels on a cured Rust Bullet Coating?

 

 

 

1. What is the difference between Rust Bullet® standard formula (Gold Label) and Rust Bullet® Automotive formula (Silver Label)?

 

Both Rust Bullet® and Rust Bullet® Automotive are industrial strength protective coatings. They have the same patented anti-corrosive properties and will out perform any other rust inhibitive, protective coating on the market.


Rust Bullet Automotive is formulated a bit thinner than the Rust Bullet standard formula to easily flow through an HVLP auto finishing spray system. Rust Bullet Automotive has more metal and will produce a smoother finish typically desired for automotive projects.

 

 

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2. Should I Apply Rust Bullet only where Rust is Apparent?


Rust Bullet is designed to protect rusted and clean metal. It is always advantageous to protect metal, even when there are no visible signs of corrosion. The automobile industry uses steel in its manufacturing wherever structural strength is needed. Ideally this steel should be protected before it starts to rust and corrode; thus preserving the strength and integrity it was originally designed to provide. Rust Bullet not only kills existing rust, it seals and protects surfaces that have not yet started to rust, providing years of prevention. Rust Bullet should be applied even where rust is not apparent to prevent the occurrence of future corrosion. If it is made of iron or steel, it will rust and corrode if left unprotected; start protecting your investment today.

 

 

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3. Can I Apply Rust Bullet Automotive with a Brush?


Yes. All Rust Bullet coatings may be applied by brush, roller, or spray equipment. A brush coat should be applied evenly without buildup in a crosshatch method (up and down and side to side) using continuous motion. Thin even coats using the crosshatch application method will produce the best results. Always keep a wet edge on the tip of your paint brush. A three to four coat brush application generally achieves a dft (dry film thickness) of 6 mils. Additional coats may be necessary to achieve the appropriate dft for your project to maintain the Rust Bullet Warranty. Roller applications result in an approximate dft of 1.5 – 2 mils per coat. An HVLP spray system applies approximately 1.5 - 2 mils with one coat, while the Airless sprayer application averages a minimum of 3 to 4 mils per coat. One gallon of Rust Bullet or Rust Bullet Automotive covers approximately 400 sq. ft. with one coat.

 

 

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4. How do I Apply Rust Bullet Automotive with an HVLP Spray System?


Rust Bullet Automotive applied through HVLP spray equipment using a 1.7 to 2.0 tip with 40- 60 psi will achieve a dft of approximately 1.5 - 2.0 mils per coat. It is important to run Xylene through the spray equipment prior to spraying the first coat of Rust Bullet Automotive to remove any moisture that may be trapped in the equipment. After the application of each coat of Rust Bullet Automotive, flush the gun or submerge the tip in Xylene. It is important to keep the equipment and sprayer clean. If the spray gun has a filter, it must also be cleaned. Toluene may be used if Xylene is not available.

Application equipment must be cleaned immediately after use to avoid damage.

 

 

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5. Why Do I Need to Apply Multiple Coats of Rust Bullet?


As Rust Bullet cures it expels solvents and releases a carbon dioxide gas while dehydrating the rust. The first coat of Rust Bullet soaks through the rust down to the metal below, encapsulates the rust, and dehydrates it. The first coat must be applied generously enough over the rust for this process to take place. As the first coat dries and gases off, tiny pin holes may form in the coating. The second coat is critical to fill any pin holes and seal the surface with an air tight, armor like shield of protection. If the pin holes are not sealed after the first coat, air and moisture may penetrate the coating exposing the surface to further damage. Apply additional coats to achieve the desired dft for the appropriate protection for the project.

 

 

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6. When Do I Apply the Next Coat of Rust Bullet or Rust Bullet BlackShell®?


When applying additional coats of a Rust Bullet coating, the previous coat should not be wet or tacky; if you are unable to transfer the coating to a gloved finger, the surface is ready for an additional coat. Approximate drying time between coats is two (2) to four (4) hours for Rust Bullet, and six (6) to ten (10) hours for BlackShell, depending on humidity levels. When excessive wet film is applied, additional cure time will be necessary. Rust Bullet Coatings are moisture sensitive; in high humid conditions of 80%+, Rust Bullet will cure much faster than it will in lower humidity. When applying additional coats from one day to the next, especially in the morning, make sure there is no dew or condensation on the previous coat. The surface to be coated must be completely dry. It is important that corners, edges, and heavily pitted areas are adequately covered. When Rust Bullet cures, it pulls tight to the center; therefore, it is particularly important that edges and corners are sufficiently coated.


Rust Bullet® Rapid Fire Accelerator can be added to the Rust Bullet Standard and Rust Bullet Automotive formulas to decrease the normal recoat time of 2 to 4 hrs to approximately 30 to 40 minutes per coat; and to Rust Bullet BlackShell to decrease the normal recoat time of 6 to 10 hours to approximately 1 hour. Rapid Fire makes it possible to apply multiple coats of Rust Bullet in a single day and reduces project completion time by as much as 80%. Rust Bullet coatings accelerated with Rapid Fire are designed for spray applications and can be applied with either an HVLP Spray System or an Airless Spray System.

 

 

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7. Can Rust Bullet be used as a Primer?


Yes. Rust Bullet can be used as an automotive primer. Before applying a finish color to a surface coated with Rust Bullet, we recommend wet sanding the surface. Wet sanding may be achieved by using 150 to 400 grit sandpaper. After wet sanding, apply an additional coat of Rust Bullet, wet sanding again to a very smooth surface; wait 6 - 7 hours before applying a topcoat (time may vary depending on weather conditions). Rust Bullet produces a very hard surface when curing. An alternate method to wet sanding Rust Bullet is to apply a sandable primer to the final coat of Rust Bullet. This will accomplish two things: remove any imperfections in the coated surface and provide a surface that is easier to sand smooth. It will also allow you the luxury of applying the final color whenever you choose to do so. Many Body Shops use this method to save time and work.

 

 

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8. Is Rust Bullet Compatible with Automotive Fillers, Fiberglass, and Primers?


Yes. Body fillers, fiberglass, and automotive primers may be applied directly over Rust Bullet. Two coats of Rust Bullet should be applied to the metal surface. The body filler, fiberglass, or primer should be applied directly over the second coat of Rust Bullet between 24 to 48 hours. If more than 72 hours have lapsed, the Rust Bullet coating should be etched with Rust Bullet® Metal Blast (simply spray it on, wait 15-30 minutes, either hose it off or wipe it off with warm water and a shop towel, and let dry completely), or sanded with 100-150 grit sandpaper, before applying the filler, fiberglass, or primer, to ensure proper adhesion. This 72 hour period is decreased in areas with higher humidity levels. After the application of the filler, fiberglass, or primer, an additional coat of Rust Bullet should be applied to seal and protect the entire surface.

Rust Bullet can be applied over existing fillers, fiberglass, or primers after scuffing the surface with 100-150 grit sandpaper or sanding block. Fillers have a tendency to absorb moisture which will cause further rusting of the metal and bubbling of the filler if applied directly to a rusted area that has not been protected with Rust Bullet. Rust Bullet works best when it is in direct contact with the metal.

 

 

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9. Can a surface coated with Rust Bullet be welded?


To ensure the welded metals are properly bonded, the Rust Bullet coating should be removed to expose the bare metal. It is possible to join two Rust Bullet coated metals by welding without removing Rust Bullet; the metal will join together but may not achieve the strong bond expected by the welding process. If metal coated with Rust Bullet, or another coating, is welded without removing the existing coating, the extreme heat involved in the welding process will disintegrate the coating possibly releasing harmful gases; therefore, the appropriate safety precautions, such as wearing a gas mask and safety goggles, must be followed. After welding, Rust Bullet must be reapplied over the welded area to ensure complete protection of the entire surface.

 

 

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10. What should I do if I waited too long before applying the next coat of Rust Bullet?


Drying time between coats of Rust Bullet is approximately two (2) to four (4) hours. Drying time between coats of BlackShell is approximately six (6) to ten (10) hours. Drying time varies depending on humidity levels. If more than 72 hours have lapsed since the previous coat of Rust Bullet, the coated surface should be etched with Rust Bullet Metal Blast (simply spray it on, wait 15-30 minutes, either hose it off or wipe it off with warm water and a shop towel, and let dry completely), or scuffed up with a 100 to 150 grit sandpaper or sanding block to allow proper adhesion of an additional coat of Rust Bullet. This 72 hour period is decreased in areas with higher humidity levels. Remember, the surface to be coated must be completely dry.

 

 

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11. What Steps are Required when Applying a Top Coat over Rust Bullet?


Ideally, a topcoat should be applied between 24 to 48 hours after the final coat of Rust Bullet. It is necessary to allow enough time for the curing or gassing off process to complete. The application of a top coat before this process is complete, may result in dimpling of the surface and an undesirable finish. If more than 72 hours have lapsed, the Rust Bullet coating should be etched with Rust Bullet Metal Blast (simply spray it on, wait 15-30 minutes, either hose it off or wipe it off with warm water and a shop towel, and let dry completely), or lightly sanded with 100-150 grit sandpaper, before applying the topcoat, to ensure proper adhesion. This 72 hour period is decreased in areas with higher humidity levels.

If a spray application of Rust Bullet has been accelerated by adding Rust Bullet® Rapid Fire Accelerator, a topcoat may be applied approximately one hour after the final coat of the accelerated Rust Bullet coating has been applied.

If you are using a premium finishing paint and the manufacturer has specific primer requirements, it is recommended you apply the primer over Rust Bullet after the surface has been scuffed up and wet sanded. Rust Bullet is an excellent adhesion promoter and enhances the adhesive properties of almost any topcoat paint.

Rust Bullet and Rust Bullet Automotive are metallic gray in color and UV resistant; it is only necessary to apply a topcoat if you desire a different color other than metallic gray. Rust Bullet BlackShell is formulated specifically as a topcoat for both Rust Bullet Standard and Rust Bullet Automotive formulas if a smooth gloss black finish is desired.

BlackShell is scratch and chip resistant, UV resistant, as well as, resistant to Acid Splash and Chemical Solvents. BlackShell is an excellent protective stand alone coating, requiring no basecoat or topcoat; however, the combination of BlackShell over Rust Bullet or Rust Bullet Automotive will provide the ultimate surface protection.

 

 

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12. What is necessary prior to applying body paint?


The surface should be wet sanded with very fine sandpaper prior to applying the desired automotive finish paint. Always follow the finish paint’s manufacturer’s recommendations on primers and sealers. Recommended primers may be applied directly to a scuffed up Rust Bullet surface.

 

 

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13. Is Rust Bullet Appropriate for Undercoating my Vehicle?


Both Rust Bullet and Rust Bullet Automotive are ideal for undercoating a vehicle and will provide outstanding protection against corrosives and abrasives. Use the Rust Bullet Automotive formula if you are using HVLP spray equipment for the application. Rust Bullet BlackShell is an excellent gloss black topcoat for the undercarriage of a vehicle. BlackShell is specifically designed as the optimum topcoat for Rust Bullet or Rust Bullet Automotive.

 

 

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14. Is Rust Bullet recommended for use on gasoline tanks?


Rust Bullet is not affected by gas itself. Rust Bullet was not designed as a tank sealer on the inside of a tank. We have not tested for this application and can offer no promise as to what the outcome will be if used as such. Rust Bullet can be used on the exterior, but it was not designed for internal use on a gas tank.

 

 

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15. Is Rust Bullet recommended for use on an exhaust system?


After curing, all Rust Bullet coatings have a service temperature range of 314°F (157°C) continuous, and can tolerate maximum temperatures between 617°- 662°F (325°-350°C) for up to 72 hour periods. Rust Bullet provides excellent protection for most engine components; however, is not recommended for coating exhaust systems due to the excessive heat produced on headers, exhaust manifolds, catalytic converter or exhaust pipes.

 

 

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16. Can I apply Rust Bullet under a Truck Bed Liner?


Yes. Rust Bullet provides excellent surface protection under bed liner material. Apply Rust Bullet according to the application guidelines. As with the addition of any topcoat or other product, if 72 hours have lapsed after the final coat of Rust Bullet, the surface should be etched with Rust Bullet® Metal Blast, or scuffed with 100-150 grit sandpaper or sanding block to ensure proper adhesion of the liner material. This 72 hour period is decreased in areas with higher humidity levels.

 

 

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17. What are the effects of Fuels on a cured Rust Bullet Coating?


Fossil fuels, such as refined oils (gasoline, diesel, jet fuels, and kerosene) will not affect the integrity of the cured Rust Bullet Coating. Additionally, renewable fuels such as Biodiesel and Ethanol will have no adverse affect on substrates coated with Rust Bullet Products.

 

 

 


IMPORTANT POINTS TO REMEMBER WHEN USING RUST BULLET PRODUCTS


Never allow sweat, rain, mist or other contaminates to fall into a Rust Bullet coating. Even
a drop or two can drastically affect results.


Rust Bullet coatings are ready to use right from the can. Rust Bullet coatings should be stirred thoroughly for at least 3 minutes or until completely uniform and homogenous (avoid whipping air into product). Shaking the container prior to application may cause the formation of bubbles in the finish of the coating. Never stir the product by mechanical means; this will trap air molecules containing moisture between the coating and the surface causing improper curing and possible coating failure. Pour out of the can what you intend to use in the next 45-60 min. Remember to keep the lid on the remaining product.


Never allow lacquer thinner, vinyl thinner, epoxy solvent, or any alcohol or unapproved solvent to enter a Rust Bullet coating.


For clean-up use only clean Xylene, Toluene, or MEK.


Never neglect to purge all paints, moisture, or debris from equipment before spraying a Rust Bullet coating.


Never apply a Rust Bullet coating while raining or under threat of rain.


Rust Bullet coatings do not require a topcoat. If one is desired, wait 24 to 48 hours after the application of the final coat of Rust Bullet.


Only pour out what you intend to use in one hour and replace the lid immediately. Wipe clean any coating from the rim of the container before resealing.


Never pour back into the original container; any Rust Bullet coating that has been exposed to outside air for any length of time, as this will destroy the remaining product.


Care should be taken to ensure that new unopened containers or left-over partial containers are kept sealed. Heavy Duty Plastic Wrap can be placed over the top of the remaining coating with the excess plastic exceeding beyond the rim of the container. This will displace as much air as possible from the remaining coating and will help prevent the lid from permanently sealing closed.

 

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Please contact our Customer Service Department at 800-245-1600
or info@rustbullet.com with questions, concerns or comments.


Rust Bullet, LLC
300 Brinkby Avenue, Suite 200
Reno, NV 89509
USA
www.RustBullet.com

 

 

 

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