How To Prevent Rust In Your Vehicle

Table of contents

1. Introduction
2. Step 1 – Sprays & Lubricants
3. Step 2 – Inspecting Problem Areas
4. Step 3 – Paint Sealants
5. Step 4 – Fixing Stone Chips
6. Step 5 – Proper vehicle housing and coverage
7. Step 6 - Proper washing and vehicle maintenance
8. Step 7 – Electronic Protection
9. Conclusion
10. Disclaimer

Introduction

Would you like the freedom to drive anywhere without fear of your vehicle rusting out?
If you’re currently living on or near the beach, in or around snow and salted roads or
simply in harsh environmental conditions, your vehicle is at risk of rust damage. This guide
aims to take you through some basic information to better understand your situation and
equip you with the knowledge needed to get one up on rust. Before we start though, let
us tell you a little about who we are and what we stand for.

1. Who and what is ERPS?

ERPS has been manufacturing Electronic Rust Prevention Systems, right here in Australia
since 1996. We have had the privilege of dealing with thousands of amazing customers,
worldwide, who have helped us establish ourselves as a leader in our industry.
Throughout, we have been on mission to improve and develop our systems and ensure we
are delivering the best quality product for our customers.

2. What is rust?
Rust definition: Rusting refers to the form of corrosion found in Iron and its alloys. Over
time, Oxygen steals Electrons from Iron and causes it to rust. This process can be pretty
tricky to understand, but put simply:

Iron + Oxygen = Rust

The addition of an electrolyte containing, salt water, acid rain, or simply just moisture,
only speeds things up.

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 Step 1: Sprays & Lubricants

If you’re a regular home handyman or DIY’er, chances are you’ve got a can of WD40 or
CRC sitting around at home somewhere. These products are generally used to undo seized
bolts or lubricate moving components.

But did you know that these sprays can be used to inhibit rust? Yep, these multipurpose
sprays really are a miracle cure for many ailments. In addition to lubricating, they double
as a rust preventative agent by repelling water and oxygen from bonding with the metal
surface.

Ideal for protecting things like headlight or fan-belt adjustment screws, alternators, fuse
boxes and other electrical components within the vehicle. The light nature of these sprays
also means they can be used more sparingly. In terms of time vs reward, you really can’t
beat a quick spray down, from one of these agents.

For a more heavy-duty approach, we recommend using lanolin as a protective coating and
water dispersant for areas such as the inside of doors and cavities. Lanolin products are
non-toxic and biodegradable, ideal for use in environmentally sensitive areas. They feature
good capillary action, and spraying allows the product to get into hard to reach places.
Once applied, the protective coating remains proactive in warm conditions. If the film is
scratched or broken, the product flows in to re-seal the surface. The substance is fairly
gooey and very sticky. For this reason, we don’t recommend it for exterior use on the
vehicle as it can become a sand-magnet. Lanolin can also be used on: metal, timber,
fibreglass, plastic, leather, rubber and vinyl surfaces.

The following exerts have been taken from their respective websites:
CRC: - https://crcindustries.com.au
CRC 5.56 is a multi - purpose product with superior penetrating power that breaks through
rust and corrosion while it clears away scale and dirt. Eliminates the need for many
disassembly operations. Lubricates for smooth action, and silences annoying squeaks and
squeals. Protects metals against corrosion and displaces moisture to help start wet
engines.

Lanolin:

• Marine grade lubricant and protectant penetrate

• Lubricates and protects wire ropes and slings
• Non-fling lubricant and protectant for high speed & load bearing chains (X-ring & O-
ring)
• Spray on anti-seize

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 • Protection of electrical components & connectors, including battery terminals,
boxes, connectors, outboard motors and pumps – nonconductive to 70kV
• Cable pulling lubricant
• External storage protection
WD40: - https://wd40.com/
Suitable for:
• Auto, truck and motorsports
• Automotive maintenance and repair
• Boating and water-sports
• Construction
• Home and Garden
• Maintenance, repair and overhaul
• General Garage and workshop use

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 Step 2 – Inspecting Problem Areas

Most of us understand the importance of inspecting our vehicles oil, water, tyre pressure
or brakes regularly throughout the year. But how many of us would actively inspect for
rust? As much as it can be a chore, regular undercarriage inspections can go a long way in
preserving and prolonging your vehicle. So now the question is…what am I looking for?

1. Paintwork damage from rocks, sand or other debris:

Paintwork is the main protectant of a vehicles steel frame and once this is removed or
damaged, the rate of rust occurring is drastically increased. Without this layer of
protection water, salt, sand and moisture can get a much greater foothold in accelerating
the rusting process. By inspecting your vehicle and fixing up damaged paintwork, rust
damage can be dramatically reduced. (See step 4 for more info)

2. Window Rubbers

Some aftermarket windscreen and window rubbers currently on the market can be of poor
quality. Even the smallest crack or detachment can be all it takes for moisture to set in
and really cause trouble. If water enters and becomes trapped behind the rubber it will
develop quickly and eventually show itself in the form of rust around the edge of the
window rubber. Window seal replacement is a fairly inexpensive and simple process for
the value it provides, so be sure to add it to your checklist when inspecting your vehicle.

3. Door Drain Holes

When a car is washed or encounters rain or snow, water can seep in past window seals
and get inside the doors of the vehicle. This water is supposed to exit through drain holes
at the bottom of the door. However, if these holes become clogged by dirt or debris and
water or moisture can’t escape, it can become a corrosive nightmare for the vehicle
owner. Some vehicles are more prone to this as they have too few or too smaller drain
holes, so make sure to examine these when doing your inspection.

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 Step 3 – Paint Sealants

In addition to sprays and lubricants, there are a number of liquid products that can help in
the war against corrosion. Paint sealants are designed to stop paintwork degradation and
provide an additional layer between oxygen and moisture and your vehicle. These
solutions are DIY friendly and will also help keep your paintwork in top condition!

Du-Cote is a paint protection program, designed to protect the new vehicle’s paintwork
against fading, oxidation, corrosion, staining, pitting, petrol, oil & detergents.
As paint ages it becomes more porous and allows atmospheric moisture through to the
bare metal underneath. These conditions are conducive to rust forming and the paint
losing its luster and protective qualities.

When buying a new vehicle, paint protection is an integral part of the aftermarket package
which typically costs around $500. For a fraction of the cost you can achieve the same
results by applying Du-Cote yourself. It’s as easy as polishing the car.

In the past few years, a number of vehicle manufacturers have been using acrylic (water
based) paints and it is therefore advisable to protect your new vehicle’s paint.
By applying Du-Cote to your existing vehicle you can increase its resale value by
rejuvenating the Duco and extending the life of the painted surfaces.

Du-Cote: - https://www.erps.com.au/product/du-cote-plastic-bottle-250ml-paint-sealant/

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 Step 4 – Fixing Stone Chips

Getting a stone chip whilst driving can ruin your day pretty quickly. However, if left
unattended it can do a lot more damage both to your vehicle and your wallet. Additionally,
if you’re a fan of Beach 4WD’ing other factors like sand and other debris (sticks, stones,
etc) can pelt the bottom of your vehicle and leave your chassis worse for wear. The
following 3 step guide will break down the cheapest and simplest way to stop rust before
it sets in:

1. Remove any flaky rust or loose scale.

Using either some fine grit sandpaper, steel wool or a razor blade – carefully remove any
surface rust that is peeling or flaking off. Be careful not to damage any more paintwork or
remove anything unnecessarily.

2. Apply Undercoat to the damaged area

Locate a suitable undercoat compatible with the top coat and apply it using a brush,
cotton bud or a small rag.

3. Locate and apply the correct colour touch up paint to the affected area

Many manufacturers provide the details for the correct colour match near the VIN number.
Once you have acquired a bottle of touch–up paint from a local automotive dealer, you
can apply it to the affected area using a small brush. Allow to dry and there you have it; a
touched up and home DYI’s stone chip repair!
Note: Be careful in locating the correct colour paint for your vehicle. If the colour is not
exactly the same, it will stand out in direct sunlight.

Undercarriage Protection with Xtra-Cote: - (Base Metal Sealant & Rust Inhibitor)
Xtra-Cote is a very unique product in the fight against corrosion. It is a sealer that
penetrates and adheres to the base metal profile. It fights rust by repelling air and
moisture and as a result, greatly reduces the amount of susceptibility to rust. One of the
most valuable properties of Xtra-Cote is that it can be painted directly onto rusty surfaces
provided any loose or flaky rust has been removed (i.e. wire brushed). It can be used as a
primer or top coast and dries clear. The application can be by brush or conventional spray
gun. Depending on temperature and humidity, Xtra-Cote will be touch dry in 1-2 hours
and completely dry in 6-24 hours. For further information phone 1800 332 899.

Applications & Method of Application:

Xtra-Cote can be used to protect and restore damaged metal surfaces such as:
• Rust damaged surfaces
• Motor vehicle underbodies
• Stone chips
• Boat trailers
• Air conditioners
• Irrigators

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 Step 5 – Proper vehicle housing and coverage

We told you this guide would be simple! However, just because something’s simple,
doesn’t mean it’s easy. There are many benefits to garaging your vehicle including:

• Protection against the elements – such as rain, snow, wind

• Keeps vehicle from the sun and temperature extremes – which can rapidly age your
vehicle
• Protection from dings/scratches – which, if left unattended, give a foothold to rust
• Stops birds, bats or other creatures from doing their business on your vehicle
So, there’s a fair few wins for putting your vehicle undercover. However, for a lot of us
who own multiple vehicles, housing them all isn’t an option. A popular and widely
accepted method of vehicle protection is a simple car cover. Benefits of car covers include:

• Affordable alternative to building more car ports

• Protects paint from the elements
• Helps prevent scratches/paint chips caused by stray bikes, cars, etc
• Help protect finish and keep waxes/polishes intact for longer
• Protects vehicle being scratched by cats, possums or other animals
There is, however, one large downside of using a cover for your vehicle. They can trap in
moisture and speed up the rusting process. This isn’t always common knowledge, so make
sure to invest in a Breathable car cover. This will give you all the benefits of protection,
without the risk of more rust!

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 Step 6 – Proper washing and vehicle maintenance

It doesn’t get much simpler than giving your vehicle a nice, thorough wash down. The
frequency at which you wash your vehicle can depend on a number of factors:

• Location – where you live and where you drive

• Frequency and distance of drive – What is your daily/weekly routine like?
• Weather – Regularly, what kind of weather are you in?
• Storage of the vehicle – garaged, covered, on the street, etc
• Appearance – Do you prefer a shiny vehicle or just to wash it when it needs it?
In addition to the recommendations laid out in step 2, there are many locations that
require extra attention – especially at the car wash:

1. Chassis Rail
If you’re an avid beach driver, then this one is nothing new. Sometimes a Car Wash
and/or underbody spray is available as you come off the beach, however, a full and
thorough wash should be undertaken as soon as practical. Often neglected simply because
of how difficult it is to access, chassis rails often require the most attention during the
wash.

Sand and salt water become trapped inside the chassis rails and unless washed out
thoroughly, will start to form rust internally. This may not be apparent until the rust begins
to break through the chassis rails and by this time it is too late, as you now have a serious
problem.

A high-pressure wash will help, but there is no substitute for flow. Use a high-volume
water hose to flush out all those hard to get at areas, such as the inside of chassis rails
and cross members. Drop down your spare wheel, (if mounted under the vehicle) washing
both the wheel itself and the space it lives in.

Be sure to wash out areas such as on top of fuel tanks, where salt and sand can sit. Don’t
forget steering components, shock absorbers, brake calipers and any component with
moving parts or cavities where salt can stick. Attention to detail and a dedicated effort in
this area will pay long term dividends in preserving your vehicle.

2. Cross-members
As with chassis rails, Cross Members can often be made of box section material, meaning
they can trap water and salt inside. Wherever possible force the water / hose up inside the
cross member through any holes or joints available.

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 3. Wheel arches
These are often a common spot for rust to set in on a vehicle. By checking not only the
arches, but also the bumper and other surrounding areas, you should be able to spot any
hidden dirt, mud, sand or other debris. Giving this area, some extra attention will pay
dividends.

4. Wheels
Due to dirtiness and lack of clear vision, wheels can often get overlooked and neglected.
Remove the wheels (don’t forget the spare), thoroughly wash the wheels (inside and out),
removing any build-up of mud or sand.
While the wheels are off, wash the brake callipers and discs, ensuring you wash any sand,
salt and mud from around the brake pads themselves.
Ensure the mating surface between the wheel and the hub (where the wheel attaches to
the vehicle) are especially clean. And don’t forget a little lubricant on the wheel studs/nuts
before the wheels go back on.

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 Step 7 – Electronic Protection

Without trying to pedal our own goods – we couldn’t honestly and thoroughly write this
guide without mentioning the importance of electronic rust prevention. All steps in this
guide are built to complement one another, and this one is no different.

By providing a negative external charge to the vehicle, an ERPS will prevent your vehicle
from oxidizing, and ultimately - rusting. Further benefits of an electronic rust prevention
system include:

• 24/7 protection – fit it and experience complete vehicle protection

• No re-applications – unlike sprays or coatings, once fitted, the system shouldn’t
need any further attention.
• The system has no moving, wearing or sacrificial components and therefore
requires the minimum of maintenance. Maintenance is limited to a monthly check of
the LED indicator light on the electron generator and a twelve-month inspection of
the vehicle and system.
• Helps protect all aspects of the vehicle – such as brakes, chassis and paintwork
• The system will both prevent new rust from forming as well as slowing the
development or spread of existing rust.

The major advantage electronic systems have over conventional sprays is that they fight
rust at the source. Where sprays can be penetrated, chipped off or worn down, a good
electronic system will continually protect against rust in all situations. When used in
conjunction with coatings and sprays, such as Xtra/Du-Cote, rusting in a vehicle can be
drastically reduced or even nullified.

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 Buyer Beware:

If you’ve done any research online regarding Electronic Rust Prevention, you’ve almost
certainly heard some of the following:

‘It can’t work – the science behind the system doesn’t support it’
‘It has to be submerged in water/soil for the system to work’
‘It’s just a flashing light that does nothing’

There is seemingly a large amount of misunderstanding and lack of knowledge regarding

electronic rust prevention in motor vehicles.

Currently there are 3 types of rust prevention technology that utilise an electrical charge:
1. Cathodic Protection – Suitable for submerged pipelines, ship hulls, underwater
structures.

2. Impressed Current – pipelines, ship hulls, steel and concrete structures, etc

3. Capacitive Coupling Technology – Suitable for vehicles, machinery and other ‘free
air’ structures.
Though both cathodic and impressed current technologies work, they are NOT suitable for
free air structures like vehicles. This has led to a plethora of misinformation and skepticism
of whether electronic rust prevention systems for cars actually work.

When purchasing an Electronic Rust Prevention System, make sure that the system utilizes
Capacitive Coupling Technology! Tried, Tested and Proven over the past 20 plus
years. For more information visit https://www.erps.com.au/information/basic-guide/

Conclusion:

We hope that this guide has granted some new-found, practical knowledge regarding
keeping your vehicle safe from rust. For any questions or inquiries, feel free to contact us
online at our website www.erps.com.au or via our toll-free number 1800 332 899

Disclaimer:

All information presented in this Ebook is written as a guide to prevent your vehicle from
rust. All advice and recommendations are given as a general outline based on research
and our own understanding of rust and the process of corrosion.

Electronic Rust Prevention Systems (Australia) Pty Ltd does not accept responsibility for
any vehicle damage, corrosion or negative outcomes incurred whilst following this guide.
For more information, clarification or recommendations regarding corrosion prevention,
please contact our staff directly on 1800 332 899.

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 About the Authors:

Jeff Eastwood Vicki Barber

Managing Director Accounts & Admin

Steve Carter Michael Eastwood

Senior Technician Marketing

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