Prep Rusty Metal Patio Furniture for Paint (80–400 Grit, Chip-Free Finish)

Outdoor chairs and tables take a beating—rust blooms under flaking paint and new coats peel fast if you don’t prep right. This guide shows the exact grit sequence and technique to strip rust, feather edges, and lay the groundwork for a durable, chip-resistant finish.

Before You Start

• Wash with degreaser, rinse, and dry completely. Work in bright shade so you can see the scratch pattern.
• Protect nearby surfaces and move fabrics/cushions far from the sanding area.
• Have a rust-inhibiting metal primer ready the moment you finish sanding.

Grit Progression (Dry or Damp Sand)

• 80 grit — strip loose paint and scale, flatten scabs.
• 120 grit — remove deep 80-grit lines; refine transitions.
• 220 grit — feather edges where old paint meets bare metal.
• 400 grit — final pre-primer pass for a uniform surface.

Step-by-Step

1. Knock down rust and flakes (80 grit). Use straight, overlapping strokes. For stubborn spots, a wire brush helps expose solid metal. When you need fresh paper, a 80-grit refill like Grit 80 — 25 Pack keeps removal fast and even.
2. Smooth and de-ridge (120 grit). Light pressure only—you’re erasing 80 marks, not thinning metal. Keep edges crisp around welds and curves.
3. Feather for invisibility (220 grit). Widen the blend 5–10 mm past each transition so the primer doesn’t telegraph a step. For consistent results, step up with Grit 220 — 25 Pack.
4. Prime-ready finish (400 grit). Quick passes to tighten the scratch pattern to a fine, even haze. A clean 400 like Grit 400 — 10 Pack helps paint lay flat and resist chips.
5. Clean and prime. Vacuum, wipe with a lint-free cloth, then prime immediately to seal out moisture. Follow with your topcoat per can directions.

Pro Tips

• Change direction with each grit (e.g., lengthwise, then diagonal) so leftover scratches are obvious.
• On thin tubing, keep the paper on a soft pad to avoid flat spots.
• Spot-treat stubborn pits after 220; don’t over-sand surrounding areas.

Watch & Learn

Result: A smooth, uniform surface that grips primer and keeps your new paint from chipping or lifting at the first sign of weather.

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