What is RustBlast?
RustBlast is a water-based rust remover and metal acid etch that dissolves rust, corrosion, metal oxides, and tarnish, then leaves a zinc phosphate base coat for paint adhesion. RustBlast handles rust removal, surface etching, and pre-paint priming in a single application, so no separate metal prep or etching primer is needed before coating.
55°F to 90°F
Ideal Working Temp
7 Days
Window To Coat After
Water-Based
Non-Flammable Formula
RustBlast applies full strength with a spray bottle, brush, roller, or backpack sprayer, and works by staying wet on the surface. Re-apply as often as needed so the metal never dries out during the dwell, then rinse thoroughly with water and let the surface dry completely.
RustBlast is Step 2 of the KBS 3-Step Rust Prevention System, sitting between KBS Klean degreasing and the RustSeal topcoat. The zinc phosphate layer RustBlast leaves behind is what gives RustSeal, and most other paints, a mechanically and chemically prepared surface to grip.
RustBlast is non-flammable, non-corrosive, biodegradable, and contains no petroleum additives. Satisfaction guaranteed!
RustBlast removes surface rust, flash rust, corrosion, metal oxides, tarnish, and light mill scale from ferrous and non-ferrous metal. RustBlast dissolves the oxide chemically rather than abrading it, so it reaches pitted areas, weld seams, and tight corners a sanding disc or wire wheel cannot physically touch.
- Surface and flash rust — Dissolves the orange oxide layer on steel, cast iron, and steel alloys, including the flash rust that forms within hours of media blasting.
- Corrosion and metal oxides — Strips oxidation from aluminum, brass, and copper with a shorter 10 to 20 minute treatment.
- Tarnish on chrome — Removes rust and tarnish from chrome trim and plated parts without abrading the plating.
- Light mill scale — Loosens and removes the blue-grey mill scale left on hot-rolled steel stock.
- Rust inside pits and seams — Penetrates pitting, weld seams, and inside corners where mechanical abrasion cannot reach.
- Rust on tools and hardware — Soak rusted tools, fasteners, and small parts for 30 minutes up to 24 hours, then rinse with a scotch brite pad.
- Rust bleed-through under old coatings — Neutralizes the rust that causes new paint to blister and lift from underneath.
- Contaminants that block adhesion — Leaves an etched, phosphated profile instead of a slick oxidized surface.
Does RustBlast Remove Heavy, Flaking Rust?
Scrape off loose rust, flaking mill scale, and peeling paint mechanically before applying RustBlast. RustBlast dissolves the rust that remains bonded to the metal, but it cannot lift scale that has already separated from the surface. On heavily rusted metal, keep RustBlast wet for 1 to 2 hours rather than the standard 30 minutes.
Does RustBlast Remove Paint?
RustBlast is not a paint stripper and will not remove sound, well-adhered coatings. Remove old paint first with KBS Strip or by mechanical means, then treat the exposed metal with RustBlast so the rust underneath is neutralized before the new coating goes on.
RustBlast combines three prep steps in one product: rust removal, acid etching, and zinc phosphate pre-priming. Most rust removers only dissolve oxide and leave bare metal that flash rusts within hours, while RustBlast leaves behind a zinc phosphate conversion coating that protects the surface and gives paint a bonded profile to grip for up to 7 days.
- Removes and neutralizes rust: RustBlast chemically converts and dissolves rust rather than just covering it, so the corrosion does not continue underneath a new coating.
- Leaves a zinc phosphate base: The slight white residue left after rinsing is zinc phosphate, the same conversion coating used in factory pre-paint lines to improve adhesion.
- Etches the surface profile: RustBlast gently etches metal to create the mechanical tooth that paints and coatings need for a durable bond.
- Works as a universal pre-paint primer: RustBlast is not limited to RustSeal. It prepares metal for most automotive and industrial paint systems.
- Enhances welding conductivity: The clean, phosphated surface RustBlast leaves improves electrical conductivity for welding and grounding.
- Non-flammable with no petroleum additives: RustBlast can be used in shop spaces where solvent-based products create fire and vapor concerns.
- Water-based and biodegradable: RustBlast cleans up with plain water and does not require solvent disposal.
- Non-corrosive in use: RustBlast does not attack the sound base metal it is applied to the way aggressive acid dips can.
- Reaches what blasting cannot: RustBlast flows into pitting, seams, tight corners, and boxed sections that abrasive media never contacts.
RustBlast works on steel, cast iron, steel alloys, galvanized metal, aluminum, brass, copper, chrome, fiberglass, and concrete. Ferrous metals get the full 30 minute or longer wet dwell, while non-ferrous metals such as aluminum, brass, and copper only need a 10 to 20 minute treatment before rinsing.
- Ferrous Metals
- Steel, cast iron, steel alloys, and galvanized surfaces. These are the primary targets for full rust removal, and they take the standard 30 minute minimum wet dwell, extended to 1 to 2 hours on heavy rust.
- Non-Ferrous Metals
- Aluminum, brass, and copper. Use a shorter 10 to 20 minute application to remove light corrosion and etch the surface, then rinse thoroughly and allow to dry completely.
- Chrome and Plated Parts
- Chrome bumpers, trim, and plated hardware. RustBlast lifts rust and tarnish from chrome chemically, which avoids the plating damage that abrasive methods cause.
- Automotive and Restoration
- Frames, floor pans, suspension components, engine parts, fuel tanks, trailer decks, and body panels. RustBlast is the standard prep step before RustSeal on any chassis or undercarriage job.
- Non-Metallic Surfaces
- Fiberglass and concrete. RustBlast etches these surfaces to improve coating adhesion, and lifts rust staining transferred onto them from nearby metal.
- Shop Tools and Hardware
- Hand tools, fasteners, brackets, and small parts. Soak them in RustBlast for 30 minutes up to 24 hours, then rinse with water and a scotch brite pad.
Buy RustBlast in the same size as the RustSeal you are using, one for one. A gallon of RustBlast preps the area a gallon of RustSeal covers, a quart matches a quart, and 8oz matches 8oz. Heavily rusted metal consumes more because the surface has to be re-wetted repeatedly across a 1 to 2 hour dwell.
| Size | Pairs With | Included |
|---|
| 1/2 Pint (8oz) | 8oz of RustSeal | — |
| Quart (32oz) | Quart of RustSeal | Sprayer |
| Gallon (128oz) | Gallon of RustSeal | Sprayer and spray bottle |
| 5 Gallon Pail (640oz) | Large or production jobs | — |
Dwell time by surface condition: 30 minutes minimum on smooth or lightly rusted metal, 40 to 60 minutes on moderately rusted metal, and 1 to 2 hours on heavily rusted metal. Non-ferrous metals need only 10 to 20 minutes. Do not let the surface dry at any point during the dwell.
What Temperature Should RustBlast Be Applied At?
Apply RustBlast between 55°F and 90°F surface and ambient temperature. RustBlast works faster and more aggressively as the metal gets warmer, so a cold garage floor in winter will noticeably slow rust removal and may require a longer dwell to reach the same result.
Pro Tip: Buy one size larger than you think you need on heavily rusted work. Keeping the surface continuously wet for a full 1 to 2 hours uses far more product than a single wet-down, and running out mid-dwell means the metal dries and you start over.
Do not skip the rinse. Rinse RustBlast off with water before it dries. Letting it dry in place builds a heavy layer of zinc phosphate powder that has to be scrubbed back off.
RustBlast differs from abrasive blasting in that RustBlast removes rust chemically and leaves a protective zinc phosphate coating behind, while blasting removes rust mechanically and leaves bare metal that begins flash rusting almost immediately. RustBlast also requires no equipment, containment, or media cleanup.
| | RustBlast | Abrasive Blasting |
|---|
| Reaches pits, seams, boxed sections | Yes, the liquid flows into them | No, media only hits line-of-sight surfaces |
| Leaves paint-ready surface | Yes, zinc phosphate conversion coating | No, bare metal that flash rusts |
| Window before coating | Up to 7 days | Typically hours, often same day |
| Equipment required | Spray bottle, brush, or roller | Compressor, blast cabinet or pot, media, containment |
| Safe on thin panels and chrome | Yes, no warping or plating damage | Risk of warping sheet metal and cutting plating |
| Time to complete | 30 minutes to 2 hours of dwell | Minutes of active work, plus setup and cleanup |
Abrasive blasting is the better choice when the metal carries heavy scale, thick layers of old paint, or deep pitting that needs to be physically opened up. Many restoration jobs use both: blast first to knock down the heavy material, then treat with RustBlast to kill the flash rust and lay down the phosphate coating before painting.
RustBlast is Step 2. Coat the treated metal within 7 days, before atmospheric moisture starts working on the freshly etched surface.
- Step 1 — KBS Klean
- Water-based degreaser that removes oil, grease, and road film. Avoid solvent cleaners, which leave an invisible residue that blocks paint adhesion.
- Step 2 — RustBlast
- Dissolves rust, etches the metal, and leaves the zinc phosphate base coat. Rinse with water and dry completely.
- Step 3 — RustSeal
- Single-component rust encapsulating coating that cures to a hard, non-porous film. Two coats minimum.
Get the Complete 3-Step Kit →
RustBlast Application Directions
Step-by-step application instructions, dwell times by rust severity, working temperature range, and the rinse procedure.
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KBS Rust Prevention Flow Chart
See exactly where RustBlast fits in the 3-step process and what to do next based on the condition of your metal.
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RustBlast Questions & Answers
The full library of customer questions about RustBlast, from zinc phosphate residue to soaking tools and using RustBlast under other paints.
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KBS Klean Directions
Step 1 of the system. How to degrease properly so RustBlast can reach the metal instead of the oil film on top of it.
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Application Guides Restoration Center
Project-by-project guides covering frames, fuel tanks, engine bays, trailers, and marine work using the KBS system.
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Before & After Photos
Real customer results showing rusted metal treated with RustBlast and finished with RustSeal.
Read Article →
Have questions before you buy? Find answers to the most common RustBlast questions below — or
order RustBlast now and get it shipped same day.
RustBlast is a water-based rust remover and metal acid etch that dissolves rust, corrosion, metal oxides, and tarnish, then leaves a zinc phosphate base coat for paint adhesion. Most rust removers stop at dissolving the oxide and leave bare metal that flash rusts within hours. RustBlast finishes the job by etching the surface and depositing a zinc phosphate conversion coating, which gives you up to 7 days to apply your topcoat.
RustBlast works on steel, cast iron, steel alloys, galvanized metal, aluminum, brass, copper, chrome, fiberglass, and concrete. Ferrous metals take the full 30 minute or longer wet dwell. Non-ferrous metals such as aluminum, brass, and copper only need a 10 to 20 minute application before rinsing, because a longer dwell is unnecessary and more aggressive than those metals require.
The slight white powdery residue is zinc phosphate, and it is supposed to be there. Zinc phosphate is a conversion coating that improves the adhesion of coatings such as RustSeal, which is why RustBlast is described as a pre-primer rather than just a rust remover. Do not scrub it off. A heavy, thick layer of powder means the RustBlast was allowed to dry before rinsing, and that excess should be washed back down.
Keep the surface continuously wet with RustBlast for a minimum of 30 minutes on smooth or lightly rusted metal, 40 to 60 minutes on moderately rusted metal, and 1 to 2 hours on heavily rusted metal. Non-ferrous metals need only 10 to 20 minutes. Re-apply as often as needed during the dwell. Do not allow the surface to dry at any point, because a dried surface stops working and has to be re-wetted from the start.
The ideal working temperature for RustBlast is 55°F to 90°F for both the surface and the surrounding air. RustBlast becomes more effective as the metal warms up, so cold metal in an unheated garage will remove rust noticeably more slowly. On a cold day, bring the part indoors or extend the dwell time and keep re-wetting the surface.
Clean the metal first with a water-based degreaser such as KBS Klean, and scrape off any loose rust, mill scale, or flaking paint. Avoid solvent-based cleaners, which leave an invisible residue that interferes with adhesion. Shake RustBlast well, then apply it full strength to a dry surface with a spray bottle, brush, roller, or backpack sprayer. Never dilute it. Keep the surface wet for the full dwell, then rinse thoroughly with water and let it dry completely.
Yes. RustBlast is used on aluminum, brass, copper, galvanized metal, and chrome, and is a common choice for removing rust and tarnish from chrome without abrading the plating. Use the shorter 10 to 20 minute treatment on non-ferrous metals rather than the full 30 minute ferrous dwell, then rinse thoroughly and dry completely. Always wear protective gloves and eyewear when using RustBlast.
Yes, rinsing is required. Rinse thoroughly with water before the RustBlast dries, which prevents a heavy layer of zinc phosphate from building up on the surface. RustBlast is water-based and biodegradable, so tools, brushes, and sprayers clean up with plain water and no solvent is needed. Let the rinsed surface dry completely before coating.
RustBlast removes rust chemically and flows into pits, weld seams, and boxed sections that abrasive media and wire wheels physically cannot reach. RustBlast also leaves a zinc phosphate coating and gives you up to 7 days to paint, while blasted bare metal starts flash rusting almost immediately. Blasting is still the better tool for heavy scale and thick old paint. Many restorers blast first, then treat with RustBlast to kill the flash rust and prep for coating.
After rinsing and drying, coat the surface within 7 days. RustBlast is Step 2 of the KBS 3-Step Rust Prevention System, so the intended next step is RustSeal applied in a minimum of two coats. RustBlast is not limited to RustSeal, though. It works very well as a metal prep and etch under most other paints, and the zinc phosphate layer it leaves improves adhesion for those systems the same way.
