Proper surface preparation is crucial for a successful Rust Bullet application. Follow these steps to ensure your surface is ready:

Clean the Surface

    • Remove Loose Material: Use a wire brush, scraper, sandpaper or media blast to remove any loose rust, scale, paint, or other debris.


  • Degrease: Clean the surface with a degreaser to remove oil, grease, and other contaminants. Rust Bullet Metal Blast is great option as a cleaner and conditioner for your metal surface. You can also use a mixture of gentle detergent, such as dish soap, and water. Rinse thoroughly with clean water and allow it to dry completely.

Surface Profile

    • Smooth Surfaces: For smooth, non-porous surfaces (like polished metal), create a profile for better adhesion. Use 80-100 grit sandpaper or a similar abrasive to scuff the surface. Metal Blast will not only clean, but also etch your surface, eliminating the need for sanding.


  • Rusty or Pitted Surfaces: Heavily rusted or pitted surfaces should be cleaned more aggressively to remove all loose material. However, Rust Bullet can be applied directly over rust, so removing all rust is not necessary.

Remove Dust

  • Dust Removal: After cleaning and profiling, remove all dust and debris using a vacuum, tack cloth, or compressed air.

Dry the Surface

  • Ensure Dryness: The surface must be completely dry before application. Any moisture can affect the adhesion and performance of Rust Bullet.


  • Protect Adjacent Areas: Use painters tape and plastic sheeting to mask off areas that should not be coated.

Application Tips

    • Stir Thoroughly: Stir Rust Bullet thoroughly by hand until homogenous (approx. 3 minutes) before use. Do not shake and do not use electric or mechanical means to stir.


    • Apply Evenly: Use a brush, roller, or spray gun to apply Rust Bullet in thin, even coats. Overapplying can lead to adhesion failure and diminished product performance.


    • Multiple Coats: Apply multiple thin coats rather than one thick coat for better protection. Rust Bullet requires a minimum 2 coat application, additional coats should be applied to achieve the appropriate DFT (dry film thickness) for your application.


    • Drying Time: Allow adequate drying time between coats, typically two to six (2-6) hours, depending on humidity and temperature. If more than 12 hours have lapse since you last coat, you will need to allow 24 hours to cure and then lightly scuff the surface for adhesion of additional coats.


  • View “General tips for a successful Rust Bullet project” for more useful tips and advise on your Rust Bullet application.


By following these steps, you ensure the surface is well-prepared for a durable and effective Rust Bullet application. Please refer to Rust Bullet’s application and technical documents for additional details.