If you happen to have rust on your truck frame, it’s a pretty bad thing, and that issue should be addressed as soon as possible.
The truck frame can have various functions, from supporting the weight of its passengers to holding the engine and drivetrain. These are typically constructed with carbon steel alloys for maximum support.
And that’s why it’s extremely important to keep it “healthy”, if I can call it that way.
In this post, you’ll learn how to remove it from your pickup truck to keep the vehicle pristine.
How to Remove Rust
Here are the key steps I take whenever I have to remove rust from any car.
1. Inspect the Type of Rust
The frame on pickup trucks and other consumer trucks usually adopts a body-on-frame design, which means the cab and bed are installed directly to it. Drivers can check the underside of the surfaces for any visible rust or corrosion.
Scrape off a tiny bit of the debris with a screwdriver to see how it would react to the force.
Regular surface rust is often the most common kind you would see, characterized by an orange or brown film on the truck frame.
If there seems to be a more extensive layer that doesn’t come off right away, the rust may have pitted itself into the steel.
Meanwhile, if holes are right by the rusted areas, you may be dealing with scale rust. Also called structural or penetrating rust, this variation can weaken the frame and negatively impact your safety.
In the case of scale rust, it’s best to contact a professional and explore getting a total frame replacement instead.
2. Determine Your Tools
You can use jack stands directly under the frame to check and work on the truck frame with ease.
As for the actual rust removal, small-scale patches can be removed with a small rust grinder or wire brush. However, you may also want to get sandpaper to remove debris from the frame.
For future steps, add soap, rust primer, and paint into the mix. Remember to wear safety gear such as gloves, goggle,s and a dust mask to avoid the fumes of the rust.
3. Loosen Up the Rust
The next step is to loosen and remove the rust from your truck frames. You can get it off by manually removing it or sanding it. Some people may also opt for more chemical removal.
Here are their differences:
- Manual: Take a grinder or wire brush wheel and remove the rust from the frame. Remember to use this at an angle to avoid directly breaking the steel beneath. If the rust feels too stubborn, you can swap to a power drill with a wire brush attachment.
- Sanding: Sanding is another safe way to get rid of stubborn rust. You can remove stubborn rust with 80-grit sandpaper, as it’s a little more effective than the regular wire brush. Plus, you can smooth out the frame’s surface with a 400-grit one.
- Chemical: Chemical rust removers eradicate rust rather than just displace it. However, you must be careful with what you use since a solution that is too potent can harm the frame itself. Consider applying commercial rust converters. Homemade solutions involving baking soda and lemon juice can also be effective.
4. Wash Away Debris
After the rust removal process, it is time to wash the frame of any lingering debris. Make sure to use lukewarm water when dealing with the underside.
If it’s dirty, opt for a mild detergent rather than a heavy one to avoid further chemical damage.
Remember to be thorough when washing the frame. Some may like to use a scrub to expose the metal underneath. Rinse the solutions well and allow the frame to dry.
5. Check for Other Signs of Rust
Washing and drying the frame can help reveal any excess rust that may have survived the initial removal.
You can repeat the previous two steps and inspect the frame until you eliminate all the remaining rust and are satisfied with the outcome.
Some may need at least two to three repetitions to see a difference, depending on the thickness of the rust.
6. Consider Other Repairs
Studying the rust on the truck frame can help you discover other deformations or room for improvement.
Whether they came from your current removal efforts or have been there all along, seek repairs for those specific parts
With the rust gone, there’s much more visual clarity in making those additional repairs.
7. Apply Primer to the Frame
Once you’re satisfied and the truck frame is dry, remember to add a layer of primer to the mix. Adding this product can help protect the metal from corrosion in the immediate future.
Apply according to the instructions provided on the product. If unavailable, you can usually use a bristle brush to add the layer on.
Let it dry and touch up the frame with paint. And there you have it, that’s how you remove and fix rust. Of course, you should get a bit more experienced with spray painting your truck so it blends with the rest of the vehicle, but that’s a whole other topic.
Rust Prevention Methods
Once you’ve removed the rust, keeping it from coming back should be your next priority. Moisture is the main enemy here. If possible, park your truck in a garage or under a quality cover, especially during winter or rainy seasons.
I always recommend doing a full rust inspection at least once a year. Focus on the undercarriage, frame rails, wheel wells, and any welded seams. Catching surface rust early makes it ten times easier to deal with.
Another solid method is applying a rust inhibitor or undercoating. I’ve had great results with oil-based sprays—they creep into seams and small crevices where salt and water usually sit. Just make sure to reapply it annually.
Lastly, wash your truck more often than you think, especially after driving on salted roads. Road salt is brutal and will eat through metal fast if you leave it sitting.
