What is the Stop Rust Quart Kit?
The KBS Stop Rust Quart Kit is a complete 3-step rust prevention system that cleans, etches, and permanently seals up to 50 square feet of rusted or bare metal with two coats of RustSeal. The kit contains a quart each of KBS Klean, RustBlast, and RustSeal, plus gloves, two brushes, a stir stick, and printed step-by-step instructions.
50 Sq. Ft.
Coverage at 2 Coats
3 Quarts
Klean, Blast, Seal
2 to 6 Hrs
RustSeal Recoat Window
55° to 82°F
Ideal Working Temp
Surface preparation is what separates a coating that lasts decades from one that lifts in a season, and the Stop Rust Quart Kit is built so that no step gets skipped. KBS Klean strips grease, oil, and fingerprint residue that block adhesion. RustBlast dissolves remaining rust and etches the metal, leaving a zinc phosphate profile. RustSeal then bites into that profile and seals it.
RustSeal chemically bonds to bare metal and forms a permanent, moisture resistant finish that stays flexible rather than cracking, chipping, or peeling. RustSeal is moisture cured, so continued exposure to moisture makes the cured film stronger rather than weaker. Cured RustSeal also resists acids, alkalis, salts, fertilizers, coal dust, solvents, oils, and refined petroleum products.
Independent testing puts cured RustSeal at 0.00 porosity across the entire color range and zero change after 1,000 hours of salt spray. Satisfaction guaranteed!
Stop Rust Quart Kit Video Overview
The Stop Rust Quart Kit contains seven items: a quart of KBS Klean cleaner and degreaser, a quart of RustBlast rust remover and metal etch, a quart of RustSeal in any of eleven available colors, black nitrile gloves, two brushes, a stir stick, and complete printed instructions. Nothing else needs to be purchased to finish a 50 square foot job.
- Quart of KBS Klean — Industrial strength water based cleaner and degreaser. Removes grease, oil, and fingerprint contamination that would otherwise block adhesion. Dilutes with water, and works faster the warmer the water is.
- Quart of RustBlast — Rust remover and metal etch. Dissolves surface rust and leaves a zinc phosphate coating that RustSeal grips. Dwell 10 minutes on light rust, 20 to 40 minutes on moderate rust, 1 to 2 hours on heavy rust.
- Quart of RustSeal, any color — The rust encapsulating topcoat. Choose from Gloss Black, Satin Black, Silver, Gloss Grey, Off-White, Oxide Red, Safety Green, Cat Yellow, Safety Blue, Safety Yellow, or Galvanized.
- Black nitrile gloves — Required for handling both RustBlast and RustSeal. Cured RustSeal cannot be removed from skin by any solvent.
- Two brushes — Natural bristle brushes sized for frame rails, floor pans, and suspension components.
- Stir stick — RustSeal is heavily pigmented and must be stirred from the bottom of the can, not shaken.
- Complete and detailed instructions — Printed step by step directions covering all three products.
See the full RustSeal color guide. Note: some RustSeal colors are only available in select sizes.
Do I Need to Buy Anything Else With the Stop Rust Quart Kit?
For a brush or roller job on 50 square feet, no. Water and a scouring pad or bristle brush for the KBS Klean and RustBlast steps are the only additions, and both are usually already in the shop. If RustSeal will be sprayed, add KBS #1 Thinner for the 5 to 10 percent reduction and for cleaning the gun immediately after use.
RustSeal is a single component moisture curing polymeric isocyanate that cures to a completely non-porous film measured at 0.00 porosity across the entire color range. RustSeal carries 72 to 76 percent solids, elongates 79 percent before failure, and showed zero change after 1,000 hours of salt spray at 98°F. Most rust paints are porous enamels that let moisture through.
- Applies over treated rust: RustSeal is designed to bond to tightly adhered rust that RustBlast has treated. Loose scale is removed, but the surface does not have to be taken back to shining bare metal.
- Single component: No hardener, no activator, no mixing ratio, and no pot life clock the moment the lid comes off. Stir and apply.
- Moisture cured: RustSeal pulls atmospheric moisture in to cure, so ambient humidity strengthens the film rather than compromising it.
- Non-porous barrier: Independent NACE TM0174 testing returns 0.00 porosity, meaning no path for moisture or oxygen to reach the metal underneath.
- High solids content: At 72 to 76 percent solids, more of what goes on the metal stays on the metal, which is why RustSeal builds 2 mils per thin coat.
- Flexible, not brittle: A 79 percent elongation rate lets RustSeal expand and contract with the substrate through thermal cycling from -30°F to 140°F without cracking, flaking, or peeling.
- Chemical resistance: Seven day spot contact testing showed no noticeable change against 93 octane fuel, diesel, brake fluid, hydraulic fluid, xylene, MEK, hydrochloric acid, and phosphoric acid.
- Heat resistance: Resistance to elevated temperatures rated at 500°F (260°C) per Mil-D-3134F.
- Brush, roll, or spray: RustSeal self levels well enough that brush marks flow out. Spray guidelines cover HVLP, conventional, airless, and air assisted airless setups.
- Widest non-porous color range: Eleven colors including Galvanized and four safety colors, so the sealing coat can also be the finish coat in areas out of direct sunlight.
- Mold and mildew resistant: Mil-F-52505 testing returned zero bacterial and fungus growth.
- Compatible with all paint systems: RustSeal accepts urethanes, epoxies, enamels, lacquers, fiberglass resins, water based coatings, and two component automotive refinish products. VOC compliant and lead free.
Why Does RustSeal Outperform a Zinc-Rich Primer?
Zinc rich primers protect sacrificially, meaning the zinc corrodes first and is consumed over time. RustSeal protects by barrier, sealing the metal from moisture and oxygen entirely at 0.00 porosity, so there is nothing to consume. RustSeal is also a finish film in its own right, while a zinc primer always needs a topcoat over it.
The Stop Rust Quart Kit works on nearly any ferrous or non-ferrous metal that holds a surface profile, including tightly rusted steel, sandblasted steel, cast iron, and aluminum. Typical jobs are automotive frames and floor pans, marine bilges and trailers, industrial tanks and pipework, and household railings and lawn equipment. Almost every part on a car qualifies except the exhaust.
- Automotive
- Chassis and frame rails, floor pans, wheel wells, fenders, trunk floors, engines, suspension components, axles, springs, roof drains, and door bottoms. Almost every part on a car except the exhaust system.
- Marine
- Engine rooms, hulls, masts, bilges, heat exchangers, decks, chain lockers, pumps, fuel tanks, and boat trailers. Marine work should get a minimum of three thin coats rather than two.
- Industrial
- Heavy transport equipment, steam pipes, sealed concrete, air conditioning repair, fiberglass repair, rebar coating, steel roofing, and fuel or waste water treatment tanks. Industrial applications also call for three coats minimum.
- Household
- Hand rails, support beams, lawn equipment and mower decks, garage floors, pipe work, appliances, and lead based paint encapsulation.
Can the Stop Rust Quart Kit Be Used Over Existing Paint?
RustSeal bonds to sound, well adhered paint after a light scuff with 400 grit sandpaper followed by KBS Klean. Understand the tradeoff: applied over paint rather than bare metal, RustSeal delivers a durable moisture resistant coating, but it cannot permanently seal rust it is not touching. For a permanent seal, strip the old paint chemically first, then run the full three steps.
The Stop Rust Quart Kit preps and coats approximately 50 square feet with two coats of RustSeal, which is roughly one passenger car frame. Bare wood, rough, and freshly sandblasted surfaces soak up more material, so plan on up to 50 percent less coverage on those. Material lost to mixing and brush loading also has to be accounted for.
| Surface Condition | Typical Coverage, Two Coats |
|---|
| Smooth or lightly rusted metal | Up to 50 sq. ft. |
| Freshly sandblasted metal | 25 to 40 sq. ft. |
| Rough, pitted, or bare wood | 25 to 35 sq. ft. |
Recoat window: Apply the second coat once the first is dry to the touch and does not leave a fingerprint, typically 2 to 6 hours. Past 8 hours, wait a full 24 hours and scuff with 320 grit or a green Scotch-Brite pad before recoating.
Pro Tip: Never paint out of the can. Pour a working amount into a separate steel or glass container and reseal the original can immediately. RustSeal's main resin is an adhesive and will permanently seal a lid shut. Put heavy plastic wrap between the lid and the can rim so metal never touches metal.
Doing the whole underside? 50 square feet covers a frame. For a full vehicle underbody, step up to the Large Stop Rust Kit.
The Stop Rust Quart Kit differs from a single can of direct-to-rust enamel in that the kit includes the two prep chemicals that make the coating stick: a direct-to-rust enamel is brushed straight over dirty rust and bonds only to the loose scale beneath it, while the kit degreases with KBS Klean and etches to a zinc phosphate profile with RustBlast before RustSeal is applied.
| | Stop Rust Quart Kit | Direct-to-Rust Enamel |
|---|
| Surface prep included | Yes, degreaser and metal etch both in the kit | No, sold as the coating only |
| Film porosity | 0.00, completely non-porous (NACE TM0174) | Varies, most alkyd enamels remain porous |
| Salt spray resistance | Zero change at 1,000 hours (ASTM B-117) | Varies, commonly rated at 250 hours or less |
| Flexibility | 79% elongation, passes -30°F to 140°F cycling | Typically brittle, prone to chipping on frames |
| Cure mechanism | Moisture cured, humidity strengthens the film | Air dry oxidation, humidity slows or spoils cure |
| Chemical resistance | No change after 7 days contact with fuel, diesel, brake fluid, MEK | Generally softened or lifted by fuel and solvents |
Direct-to-rust enamel is the better choice for a quick cosmetic touch up, for a surface that will live in full sun where an unprotected coating's color matters less than convenience, or when the budget rules out a full system. RustSeal is not UV stable as a final finish, so anything in direct sunlight needs a topcoat such as BlackTop, KBS Top Coater, or KBS MAXX over it.
If the coated part lives out of direct sunlight, such as a frame or floor pan underbody, nothing more is required and RustSeal serves as the final finish. Anything exposed to sunlight should be topcoated, because prolonged UV alters RustSeal's color and sheen. RustSeal's rust protection does not degrade under UV, only its appearance.
- Option 1 — Topcoat wet on dry
- Apply the topcoat once the final RustSeal coat is dry to the touch and leaves no fingerprint, usually 3 to 6 hours.
- Option 2 — Cure and scuff
- Let RustSeal cure a full 24 hours, scuff with 320 grit, then topcoat.
- Option 3 — Cure and dust
- Let RustSeal cure 24 hours, dust with Fusion Self-Etching Primer, allow 30 minutes, then topcoat.
See the Full KBS 3-Step System
How to Stop Rust and Prevent Rust
Why rust keeps coming back after ordinary paint, and what a sealed non-porous barrier does differently.
Read Article →
RustSeal: Insane Durability and Flexibility
A coated panel bent, hammered, and twisted on video to show what a 79 percent elongation rate looks like in practice.
Read Article →
Stacey David: Rust Prevention on Car Surfaces
Stacey David walks the 3-step system across body panels and chassis surfaces on a full build.
Read Article →
Lawnmower Deck Rust Removal and Painting
A small, contained project that shows the full Klean to RustBlast to RustSeal sequence start to finish.
Read Article →
RustSeal How-To: Ford Flathead Restoration
Detail work on an engine block and small castings, including how to handle tight corners and fasteners.
Read Article →
Before and After Photos
Customer frames, floor pans, and equipment photographed before prep and after two coats of RustSeal.
View Gallery →
Have questions before you buy? Find answers to the most common Stop Rust Quart Kit questions below, or
order the Stop Rust Quart Kit now and get it shipped same day.
The Stop Rust Quart Kit is the complete KBS 3-Step System in quart sizes: KBS Klean to degrease, RustBlast to remove rust and etch the metal, and RustSeal to permanently seal it. What separates it from a single can of rust paint is that the two prep chemicals are included, so the coating bonds to a properly etched surface instead of to dirt and loose scale. The kit covers approximately 50 square feet with two coats.
The kit works on tightly rusted steel, sandblasted steel, cast iron, aluminum and other non-ferrous metals, fiberglass, and sealed concrete. Typical jobs include automotive frames, floor pans, wheel wells, suspension parts, marine bilges and boat trailers, industrial tanks and pipework, garage floors, hand rails, and lawn equipment. The one automotive part to avoid is the exhaust system, which runs hotter than RustSeal's 500°F rating.
One Stop Rust Quart Kit covers roughly one passenger car frame at 50 square feet with two coats. For the entire underside of a vehicle, including floor pans, wheel wells, and inner fenders, step up to the Large Stop Rust Kit. Freshly sandblasted or heavily pitted metal absorbs more material, so expect as little as 25 to 40 square feet on those surfaces.
RustSeal is ready for a second coat once the first is dry to the touch and does not leave a fingerprint, typically 2 to 6 hours depending on temperature and humidity. At 75°F and 50 percent relative humidity that is about 2.5 hours; at low humidity it can stretch past 8 hours. If more than 8 hours pass, wait a full 24 hours and scuff with 320 grit before recoating. Full cure is 24 hours.
The ideal application temperature range for both RustBlast and RustSeal is 55°F to 82°F (13°C to 28°C). RustSeal is moisture cured, so it should be applied in moderate to dry conditions. Avoid rainy or highly humid days, because a damp surface can cause bubbling and poor adhesion. Always let the products and the part come to room temperature before starting.
Remove loose flaking rust with 320 grit sandpaper or a wire wheel. Dilute KBS Klean with warm water, apply liberally, scrub for 5 to 10 minutes, then rinse thoroughly and let dry. Apply RustBlast full strength and keep the surface wet for 10 minutes on light rust, 20 to 40 minutes on moderate rust, or 1 to 2 hours on heavy rust, then rinse and dry completely. Stir RustSeal thoroughly, pour a working amount into a separate container, and brush, roll, or spray a minimum of two thin coats at 2 mils each.
Yes. On aluminum, brass, and copper, keep KBS Klean dilution rates and dwell times to a minimum because these alloys vary widely in how they react. Follow with RustBlast for 10 to 20 minutes to etch the surface, then rinse thoroughly and dry completely before applying RustSeal. On new, smooth, or shiny metal of any type, scuff lightly with 400 grit first so the coating has a profile to bite into.
Clean up with KBS #1 Thinner or lacquer thinner immediately, before RustSeal dries. Once cured, RustSeal cannot be removed by any solvent, which is why the kit includes nitrile gloves. If RustSeal contacts skin, remove it right away with thinner followed by soap and water. Spray guns must be cleaned the moment spraying stops. Use only KBS #1 Thinner for reducing RustSeal, never lacquer thinner.
A zinc-rich primer protects sacrificially, meaning the zinc corrodes in place of the steel and is gradually consumed, and it always requires a topcoat. RustSeal protects by barrier at 0.00 measured porosity, so moisture and oxygen never reach the metal and nothing is consumed. RustSeal also functions as a finish coat on its own in areas out of direct sunlight, which a primer cannot do.
Only for surfaces in direct sunlight. RustSeal's rust protection does not degrade under UV, but prolonged sun exposure alters its color and sheen. Underbody areas such as frames and floor pans need no topcoat. For sun exposed parts, use an opaque topcoat such as BlackTop, KBS Top Coater, or KBS MAXX. A clear topcoat will not provide UV protection.
RustSeal bent, hammered, and twisted on camera to demonstrate a 79 percent elongation rate
Sam Memmolo coats a rusty frame with RustSeal and seals the inside with KBS Cavity Coater
Repairing rust at the bottom of car doors with the KBS 3-Step System, Top Coater, and Cavity Coater
