How to Sand Rusty Steel: with a Sanding Block (Budget Setup)

Getting a clean, even surface is the difference between a finish that looks “okay” and one that looks intentional. This guide shows the grit sequence and technique to sand Rusty Steel for de-burr cut edges, with simple checks so you don’t over-sand or leave deep scratches behind.

Why Sanding Matters

Sanding removes defects and leaves a controlled scratch pattern that helps your next layer bond and level. The right progression saves time because each grit only removes the scratches from the previous step.

Tools

• Sanding block or foam pad
• Vacuum or tack cloth
• Clean microfiber rags
• Painter’s tape (mask edges)
• Safety glasses and dust mask

Recommended Grit Sequence

• 80 grit — move to this grit once scratches from the previous step are gone.
• 120 grit — move to this grit once scratches from the previous step are gone.
• 180 grit — move to this grit once scratches from the previous step are gone.
• 220 grit — move to this grit once scratches from the previous step are gone.
• 320 grit — move to this grit once scratches from the previous step are gone.

Step-by-Step

1. Clean and inspect. Remove dust, wax, and oils from the Rusty Steel so the abrasive cuts evenly.
2. Start with defect removal. Use 120 Grit (100-pack) to level high spots, peel edges, or old finish quickly—stop as soon as the surface is uniform.
3. Progress through the sequence. Work through the recommended grits, sanding with light, even pressure and overlapping strokes.
4. Refine scratches. Switch to 220 Grit (10-pack) and sand until the previous grit’s lines disappear under raking light.
5. Control dust. Vacuum between grits (and wipe with a tack cloth) so loose particles don’t create random deep scratches.
6. Finish for the next coat. Use 320 Grit (25-pack) for a consistent final profile—ideal before paint, stain, clear coat, or polishing.
7. Final wipe-down. Clean the surface, then allow it to fully dry before applying the next product.

Special Cases

Edges & corners: Fold the sheet and use fingertip pressure lightly—avoid rounding crisp edges.

Curves: Wrap paper around a foam pad so contact stays even.

Wet sanding: For finer grits, a light water mist can reduce clogging (use only if the next finish and material allow it).

Pro Tips

• Mark the surface with a pencil grid; when the marks disappear, you’re evenly sanded.
• Change sheets when cutting slows—dull paper causes heat and swirl marks.
• Use consistent stroke direction per grit; change direction slightly at the next grit to spot leftover scratches.
• Don’t skip more than one grit step to avoid chasing deep scratches later.

Aftercare

• Store sheets flat and dry to prevent curled edges.
• Dispose of dust safely; some finishes produce combustible dust—keep away from sparks.
• Seal or coat soon after sanding so the surface doesn’t pick up oils or moisture.

FAQs

• What grit should I stop at for de-burr cut edges? Use the last grit in the recommended sequence unless your finish maker specifies otherwise.
• How do I know when to move to the next grit? When scratches from the previous grit are gone across the whole surface.
• Wet or dry? Wet sanding helps with clogging on fine grits; dry sanding is faster for early shaping.

Watch & Learn

Tip: watch for scratch pattern changes between grits—if you still see long lines from the previous step, stay on the current grit a little longer before moving on.

Need specific sheets for your project? Browse the full collection here: https://equalle.com/collections/all.