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Old 05-31-2015, 10:18 AM #1
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Rusting Hefty Fabworks Dual Swingout Rear Bumper

Unfortunately, this winter my rear bumper started rusting...a lot!

I'm not quite sure why, but my guess is that the cold temperature we experience up here (-40 degrees Celsius sometimes) cause microcracks in the powder coat. Water gets underneath the coating, steel starts rusting and coating starts to flake off. The water jug holder is definitely the worst. I used a flapper wheel to remove the rust on the bumper and a power washer on the jug holder. I then did a light coat of flat black paint, which blends in seamlessly and some JB Weld as a filler (instead of bondo). Once it sets, i'll sand it smooth and paint with Rustoleum Textured Black (which according to Hefty matches perfectly with their powder coat).

Any of you experience serious rusting of your bumpers? I almost wonder if the the flat textured powder coat is more susceptible because my front bumper has zero sign of rust and it is has more of a gloss finish.
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Rusting Hefty Fabworks Dual Swingout Rear Bumper-wp_20150529_003-jpg  Rusting Hefty Fabworks Dual Swingout Rear Bumper-wp_20150529_004-jpg  Rusting Hefty Fabworks Dual Swingout Rear Bumper-wp_20150531_001-jpg  Rusting Hefty Fabworks Dual Swingout Rear Bumper-wp_20150531_002-jpg  Rusting Hefty Fabworks Dual Swingout Rear Bumper-wp_20150531_003-jpg 
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Old 05-31-2015, 11:13 AM #2
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Ah the Canadian Winters just love to destroy things, between rust, rockchips and shitty roads...(I'm 50/50 Edmonton/Fort Mac)...I got no real contribution to the thread otherwise lol. Good luck with the fix!
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Old 05-31-2015, 12:51 PM #3
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That's weird, I thought powdercoating was flexible enough to move with metal expansion?
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Old 05-31-2015, 01:21 PM #4
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Quote:
Originally Posted by BlackWorksInc View Post
That's weird, I thought powdercoating was flexible enough to move with metal expansion?
To be honest, I think there were some manufacturing shortfalls. Some areas I could see no cracking at all...its almost as if they powder coated over rusty or oily metal.
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Old 05-31-2015, 02:00 PM #5
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they should stand behind their product. you obviously have enough pictures that show there is an issue with their finish work. I would continue hounding them until it was resolved.
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Old 05-31-2015, 02:01 PM #6
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Quote:
Originally Posted by dahorst View Post
To be honest, I think there were some manufacturing shortfalls. Some areas I could see no cracking at all...its almost as if they powder coated over rusty or oily metal.
You definitely have some rust happening there. Rust Happens.

It doesn't get that cold here in So Cal that we need to use road salts or gravel. Isn't some of this rust due to road salts?
Looking at your prep work I can't see how much you ground, sanded or primed. I think you need to remove all of the loose paint and rust. I see edges of paint next to the bodywork that you can not get off if it's still on the car. You may need to take the bumper off so you can do some aggressive scraping, grinding and sanding. Once all of the loose paint, rust, oils and salts are removed, then primer and paint. Good luck.
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Old 05-31-2015, 02:34 PM #7
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Quote:
Originally Posted by On Point View Post
they should stand behind their product. you obviously have enough pictures that show there is an issue with their finish work. I would continue hounding them until it was resolved.
shipping from Northern Alberta to Colorado Springs to have it repaired and back would cost nearly as much as the bumper itself did when it was new. best bet is to do the best job you can to repair the rust yourself, as he has done.

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It doesn't get that cold here in So Cal that we need to use road salts or gravel. Isn't some of this rust due to road salts?
it gets cold enough here in the winter that they generally don't use salt, since it isn't effective below a certain temp.
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Last edited by Jono.ful; 05-31-2015 at 08:03 PM. Reason: typo
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Old 05-31-2015, 02:59 PM #8
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Quote:
Originally Posted by DesertCanyons View Post
You definitely have some rust happening there. Rust Happens.

It doesn't get that cold here in So Cal that we need to use road salts or gravel. Isn't some of this rust due to road salts?
Looking at your prep work I can't see how much you ground, sanded or primed. I think you need to remove all of the loose paint and rust. I see edges of paint next to the bodywork that you can not get off if it's still on the car. You may need to take the bumper off so you can do some aggressive scraping, grinding and sanding. Once all of the loose paint, rust, oils and salts are removed, then primer and paint. Good luck.
I'm not going to go crazy...just touch up the bad spots and monitor. The flat paint blends in absolutely seamlessly so frequent touchups will be no big deal until it becomes unmanageable.

We live in a very dry climate so this rust is extremely odd. Not much salt use here, more sand because of the cold.
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Old 05-31-2015, 10:20 PM #9
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Might also want to try some POR 15 I use this on one of my other trucks that has a replacement bumper and the stuff is tough.
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Old 06-01-2015, 08:57 AM #10
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Done. Lets see how it holds up!
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Old 06-01-2015, 10:15 AM #11
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Looks like you did a nice job refinishing it. Hope it holds up for you!
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Old 03-17-2016, 10:02 PM #12
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any updates?

sorry to revive an old thread, but I'm on the precipice of ordering a hefty rear




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Old 08-28-2016, 09:37 AM #13
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Question Any updates

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Originally Posted by Jono.ful View Post
any updates?

sorry to revive an old thread, but I'm on the precipice of ordering a hefty rear

same thing here, would love to hear an update since I am seriously considering hefty

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Old 08-28-2016, 03:24 PM #14
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same thing here, would love to hear an update since I am seriously considering hefty
Be prepared for a ridiculous wait, ordered mine Mar 19 and still nothing. Can't even get an answer from them about a new eta as "12-16 weeks" has long since passed
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Old 08-28-2016, 04:13 PM #15
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Be prepared for a ridiculous wait, ordered mine Mar 19 and still nothing. Can't even get an answer from them about a new eta as "12-16 weeks" has long since passed
That is ridiculous....A couple of weeks... even a few months. But 6 months is just silly.
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