1. Assessment:
* Surface Rust: This is just discoloration and minor pitting.
* Moderate Rust: Significant pitting, some flaking, but the metal still holds its shape.
* Severe Rust: Holes, significant weakening, and the running board's structural integrity is compromised.
2. Repair Methods:
* Surface Rust (Minor):
* Wire Brush/Sanding: Remove loose rust with a wire brush (preferably a rotary one with a wire wheel attachment) or sandpaper. Wear appropriate safety gear (eye protection, dust mask).
* Rust Converter: Apply a rust converter to neutralize remaining rust and provide a bonding surface for primer. Follow the manufacturer's instructions carefully.
* Primer and Paint: Apply a self-etching primer, followed by several coats of automotive paint matched to your vehicle's color. Use several light coats rather than one heavy coat for better adhesion and a smoother finish. Top with clear coat for added protection.
* Moderate Rust (Significant Pitting):
* Wire Brush/Sanding (More Aggressive): Thorough removal of rust is crucial. You may need to use different grades of sandpaper to achieve a smooth surface. Consider using a DA (Dual Action) sander for a more consistent finish.
* Rust Repair Fillers: For deeper pits and holes, use a high-quality rust repair filler designed for automotive applications. Allow ample drying time between coats and sand smooth before priming.
* Primer and Paint: As above.
* Severe Rust (Holes, Structural Weakness):
* Replacement: This is the most likely best option. Finding a used running board in good condition at a salvage yard or online is often the most cost-effective solution.
* Fabrication/Welding: If you have welding experience, you might be able to cut out severely rusted sections and weld in patches of new metal. This is a more advanced repair and requires skill and specialized tools. If you're not comfortable welding, leave this to a professional.
* Patching (Temporary): For a temporary fix, you can use metal patches and epoxy adhesives to cover holes and reinforce weak areas. However, this is not a long-term solution.
3. Materials and Tools:
* Wire brush (rotary preferred)
* Sandpaper (various grits)
* Rust converter
* Self-etching primer
* Automotive paint (matched to your vehicle's color)
* Clear coat
* Rust repair filler (if needed)
* Safety glasses
* Respirator/dust mask
* Gloves
* Putty knife
* DA Sander (optional, but highly recommended for a smooth finish)
* Masking tape
* Cleaning rags
4. Important Considerations:
* Undercoating: Once the repair is complete, apply undercoating to the underside of the running board to protect it from future rust.
* Prevention: Regularly clean and inspect your running boards to catch rust early. Consider applying a rust preventative coating periodically.
* Professional Help: If you're uncomfortable with any of these steps, or if the rust damage is extensive, it's best to consult a professional body shop or auto repair technician. They have the tools and experience to perform a quality repair.
Remember safety first! Always wear appropriate personal protective equipment (PPE) when working with chemicals, abrasives, and power tools.
