Rust: A Midwestern T4R's Dilemma

[schnob]

After coming out of my three month lurking phase I have a common problem to deal with, the problem being rust. Overall my T4R is in pretty good shape being from the Midwest but it has a few worrisome spots (see below) and I am looking for some suggestions. My dad suggested I simply sand down the rust spots on the tailgate and the windshield, then spray paint them with a glossy-black. This worked for about a year on the first windshield patch.
As you can see, the plastic part of my tailgate is also a bit loose and there appears to be a bit of rust developing there too. I'm at a bit of a loss for what to do to this, perhaps just put some sealant on and try to make it tight again?
I appreciate any suggestions in advance!

 

[MStudt]

That's not bad at all. Sand it down, apply navel jelly, clean, prime, and paint. Navel Jelly is the only stuff that actually works on rust.

 

[Nelsonmd]

No, I think it's best you scrap her, there's no coming back from that level of rust.

It is a common problem, with many common solutions. Search here for what others have done, and try one. No one is going to be able to give you a magic bullet for this one, and nothing is going to fix it forever. Your paint method is fine, though you might have better results if you properly prime and paint it instead of just sanding and spraying. There are lots of rust converters and other rust paints you can try; you'll just have to try some and see which you like best, everybody's mileage varies on every method.

 

[schnob]

Thanks for the advice gentleman, I know nothing can permanently get rid of rust, just trying to hold it off for a bit longer.
I'll definitely have to try some navel jelly.

 

[T4R2014]

I would pull the windshield and fix ALL the rust around it. You can sand the areas you can see but the areas underneath are what matter.

 

[iowajosh]

Lots of things work on rust. You have to remove the scale for most of them to work. When removing poc marks like that, sand 1" beyond them at least. If it is coming from the backside, it is not just sand and paintable.

 

[Nelsonmd]

I would pull the windshield and fix ALL the rust around it. You can sand the areas you can see but the areas underneath are what matter.

I wouldn't do that until you need to replace the windshield. Then when you do, pull the windshield yourself, take care of the rust as best you can, then have the installer come with the new windshield. Last time I had my windshield done, the guy showed me what it looked like underneath and it was completely rusty. He didn't guarantee the windshield from leaking since it was so rusty, but it has been fine so far.

For mine, the guys said the fix would probably have to be welding in new metal.

 

[MTD]

I have rust around the windscreen on mine too... It sucks, but I will be sanding mine and then using Ospho to seal it, and then painting the roof black I think (no need to color match then...). Ospho is great stuff it will eat the rust and keep it from coming back. A family friend who restores cars for a living recomended it.

 

[schnob]

I don't really have the means or the knowledge to pull off the windshield so I'll likely pass on that for now.
This Ospho stuff has me intrigued though. So I would just use that instead of navel jelly?

 

[98OzarksRunner]

Rust that bubbles up like that comes from the inside. Simply sanding it down and painting it isn't likely to stop it. If you do sand it down, use a wire wheel on a drill or angle grinder and remove all the rust (you'll likely break through the metal). Treat it with rust converter (like Ospho) then prime it, fill it, and paint it. Also, get behind it and spray a rust sealing paint on the inside (even Rustoleum rusty metal primer is better than nothing).

Ospho is phosphoric acid. It converts the rust (iron oxide) to iron phosphate (turns it black). Be sure and rinse it off well (even though the instructions say not to) or the primer may not stick to it (epoxy primer won't - ask me how I know).

 

[schnob]

Yeah, I had figured the rust on the tailgate had come from behind. I don't have much for tools out here, would it be better to leave it alone and wait until I have access to a shop or sand it down now and do it again later in the summer?
The stuff above the windshield is of more of a concern to me. If I were to use Ospho, I would sand, apply Ospho and clean it, prime it then paint it?