Sanding Metal for Rust Removal: 60–220 Grit Sandpaper Sheets

Rust weakens metal and ruins its appearance, but it can be eliminated with the right abrasives. Using 9x11 inch sandpaper sheets, you can strip rust, smooth the surface, and prepare metal for primer or paint. eQualle’s wet dry silicon carbide sandpaper sheets are designed for aggressive cutting and consistent results.

Why Sand Rusted Metal?

Rust spreads quickly if untreated. Sanding removes oxidation and creates a clean surface that primer and paint can adhere to. Without sanding, coatings will peel or bubble over time.

Tools You’ll Need

• eQualle metal sanding sandpaper sheets
• Sanding block or orbital sander
• Wire brush (for heavy corrosion)
• Rust-inhibiting primer
• Protective gloves and mask

Best Grits for Rust Removal

• 60 grit — Removes heavy rust and paint layers. 60 Grit (25-pack).
• 80 grit — Levels the surface after coarse sanding. 80 Grit (50-pack).
• 120 grit — Refines scratches and prepares for primer. 120 Grit (25-pack).
• 220 grit — Creates a smooth, paint-ready surface. 220 Grit (100-pack).

Step-by-Step Rust Removal

1. Start with 60 grit sandpaper sheets. Sand aggressively to strip thick rust and loose paint. Use a sanding block to maintain even pressure.
2. Switch to 80 grit. Smooth the surface and remove marks left by the coarse grit.
3. Continue with 120 grit sandpaper sheets. Refine the surface and prepare metal for coating.
4. Finish with 220 grit. Lightly sand until the metal feels smooth and ready for primer.

Special Cases

For pitted rust, combine sanding with a rust converter before applying primer. On aluminum, avoid grits coarser than 80 to prevent gouging.

Pro Tips

• Always sand with steady, even strokes to avoid low spots.
• Use wet dry sandpaper sheets with water to reduce dust and heat on finer grits.
• Clean metal thoroughly before priming to prevent adhesion issues.

Aftercare

• Apply a rust-inhibiting primer immediately after sanding.
• Store leftover sheets flat in a dry place to prevent curling.
• Keep assorted grits ready for future touch-ups.

FAQs

• Can I paint directly after sanding? No—always prime first to seal the metal.
• Which grit removes rust fastest? 60 grit is best for heavy corrosion.
• Do I need bulk packs? For large projects, yes. 220 Grit (100-pack) ensures you won’t run out.

Watch & Learn

Fight rust effectively with eQualle 9x11 in sandpaper sheets. Shop the complete range in the Metal Sanding Collection.