How to Sand Metal for Polishing & Rust Removal (60, 100, 150, 220 Grit Guide)

From automotive parts to garden tools, metal surfaces often suffer from rust, oxidation, and rough finishes. Sanding is the first step to restoring shine or prepping for paint. The right grit sequence removes corrosion, smooths imperfections, and prepares metal for finishing. This guide explains how to sand metal step by step using 60, 100, 150, and 220 grit sandpaper.

Why Sanding Metal Matters

Metal surfaces corrode over time, forming rust and scale that weaken structure and ruin appearance. Sanding removes these layers and levels the surface so primer, paint, or polish can adhere properly. Skipping proper sanding often leads to premature paint failure or poor polishing results.

Tools You’ll Need

• Coarse-to-fine sandpaper (60–220 grit) – for progressive smoothing.
• Wire brush or wheel – for heavy rust before sanding.
• Sanding block or orbital sander – ensures consistent pressure.
• Protective gloves & mask – safety against sharp rust and fine dust.
• Rust-inhibiting primer – for long-lasting protection after sanding.

Best Grits for Metal Prep

• 60 grit: Aggressive rust removal and stripping paint.
• 100 grit: Refines surface after heavy removal.
• 150 grit: Smooths scratches and prepares for finer sanding.
• 220 grit: Final prep before primer, paint, or polishing.

Step-by-Step Metal Sanding

1. Remove heavy rust with 60 grit. For thick corrosion, start with 60 grit (25-pack).
2. Smooth with 100 grit. This stage clears deep scratches left by coarse grit. Use 100 grit (50-pack) for bulk use.
3. Refine with 150 grit. Levels the surface and prepares for final sanding. Try 150 grit (100-pack).
4. Finish with 220 grit. Creates a smooth, paint-ready surface. Stock up with 220 grit (10-pack).
5. Clean and prime. Wipe with solvent, then apply rust-inhibiting primer.

Special Cases

For stainless steel, avoid overly coarse grits to prevent deep scratches—start at 100 grit instead. For aluminum, use light pressure and stop at 220 grit before polishing. Heavily pitted metal may require a grinder before sanding.

Pro Tips

• Always sand in one direction for a uniform scratch pattern.
• Wet sanding with finer grits reduces dust and clogging.
• Switch sheets often—metal wears sandpaper quickly.
• Seal bare metal immediately after sanding to prevent flash rust.

Aftercare

• Store sandpaper in a dry place—moisture ruins effectiveness.
• Inspect tools after rust removal—apply oil to prevent future corrosion.
• Apply protective coatings (primer, paint, or polish) right after sanding.

FAQs

• Do I always need to start at 60 grit? Only if rust or paint is severe—otherwise start finer.
• Can I polish after 220 grit? Yes, but for mirror finishes, continue to 600–3000 grit before buffing.
• Will sanding remove deep rust pits? No—pitting may need filler or welding.

Watch & Learn

Get everything you need for rust removal and refinishing in our extra coarse sandpaper collection.