Application

SURFACE PREPARATION

The surface to be coated must be completely dry. All surfaces must be free of loose rust, paint, moisture, dirt, mildew, oily substances, wax, and loose particles. Remove any loose rust, loose paint, or loose mill scale by lightly scraping, sanding, or wire brushing. If necessary, we recommend cleaning a surface by wiping it down with Xylene or Toluene; washing with HD detergent or soap and water, or simply wire brushing the surface will also work. No additional surface preparation is necessary as Rust Bullet bonds with metal to kill the rust and form a super-tough armor like coating. Remember that the surface to be coated must be completely dry. Rust Bullet will penetrate some paints by just scuffing up the painted surface prior to application; however, Rust Bullet works best when in direct contact with the rusted surface or bare metal. Media blasting using baking powder or dry ice is the recommended surface preparation for large jobs.

  • Brush or Roller Application:
    All Rust Bullet Coatings can be applied with a brush or roller if spray equipment is not available. Always keep a wet edge on the tip of your paint brush. Apply evenly without buildup using a crosshatch method (up and down and side to side motion); nice even coats using the crosshatch application method will produce the best results.
  • HVLP Spray Gun:
    The Rust Bullet Automotive Formula is thinner than the Rust Bullet Standard Formula allowing it to flow easily through HVLP spray equipment. Rust Bullet Automotive has more metal added to provide a shiny smooth paintable finish. When applying with an HVLP spray system, use a 1.5 tip at 40 psi. A minimum dry film thickness of 6 mils must be applied to the project surface for the 10 year warranty to be valid; some applications require additional coats to achieve the appropriate dft expressed in the Rust Bullet Warranty. Prior to spraying, run Xylene through the paint holder to remove any moisture that is trapped in the sprayer. After each coat of Rust Bullet is applied, flush the gun or submerge the tip in Xylene. Application equipment must be cleaned immediately after use to avoid damage to the sprayer. If there is a filter in the gun it must also be cleaned. Approximately 24-48 hours after the application of the final coat of Rust Bullet, a topcoat may be applied. Rust Bullet is metallic gray in color; it is only necessary to apply a top coat if you desire a different color other than metallic gray. Rust Bullet BlackShell is formulated specifically to topcoat Rust Bullet if a smooth gloss black finish is desired. BlackShell is scratch and chip resistant, UV resistant, as well as, resistant to Acid Splash and Chemical Solvents. BlackShell is an excellent protective stand alone coating, requiring no basecoat or topcoat; however, the combination of BlackShell and Rust Bullet or Rust Bullet Automotive will provide unbeatable surface protection.
  • Airless & Commercial Spray Equipment:
    The best results are achieved by applying the Rust Bullet Standard Formula using an airless spray system. An airless spray application will generally produce a dry film thickness of 3 to 4 mils per coat. When using airless or commercial spray equipment to apply Rust Bullet Products, a 519 tip is recommended for big jobs and a 517 tip for medium jobs. The first digit (5) means it covers 10 inches when held one foot away from the object. The second and third digits (17 or 19) represent the size of the hole in the tip; in other words, a 517 tip has a smaller hole than a 519 tip.

    Xylene is recommended for the preparation and cleanup of all spray equipment. When the spray gun is not in use, such as between coats, it should be completely submerged in a container of Xylene. Application equipment must be thoroughly cleaned immediately after use to avoid damage; any remaining Rust Bullet will cure and likely destroy the equipment.

Airless Spray Tips

  • Rust Bullet Standard is supplied ready to stir and apply with an airless sprayer.
  • Straining through a nylon bag strainer is recommended.
  • Follow Stirring Instructions thoroughly before application.
  • Recommended tip size is 011-015 (517-519 tip).
  • Inspect all spray equipment and ensure it is clean and in good working order prior to application.
  • Flush Xylene or Toluene through pump, line, and gun to remove any existing moisture or alcohol from previous coatings or solvents. Do not re-circulate the solvent through the pump, as the solvent will be contaminated with moisture and debris; draw solvent from one container and flush into another. Never allow old solvent in the coating lines to enter Rust Bullet.
  • Ensure that minimum cure times are followed before the application of a subsequent coat. Published cure times (under normal weather conditions) are specified in the product's Engineering Data Sheet. When excessive wet film is applied, additional cure time will be necessary.

EQUIPMENT CLEAN-UP

  • Use Xylene, Toluene, or MEK for cleanup; do not substitute any other solvent.
  • Even a very small contamination of Rust Bullet with alcohol or other hydroxyl-containing solvents can destroy the moisture-cure reaction, partly or entirely, without any indication or jelling.
  • Always flush equipment clean.
  • Do not leave Rust Bullet residue as it will harden and become insoluble in solvent.
  • Clean equipment as you would with any typical two component catalyzed coating.
  • Always clean brushes and rollers thoroughly.
  • Dunking dirty equipment in solvent will not prevent the coating from curing overnight.

SAFETY TIPS

A certain degree of risk is involved in the use, or more properly, the misuse, of most industrial materials; Rust Bullet is no exception to this rule. Ensure adequate ventilation and fresh air when working with Rust Bullet coatings. Use a NIOSH Approved Respirator with an 8051 Organic Vapor chemical cartridge and an R95 filter attached with a filter cover. Filters must be changed if and when they become saturated. Wear protective clothing, gloves, and eye protection during set up, application, and clean up. Due to the superior adhesive properties of Rust Bullet, we strongly recommend that protective clothing be worn including long sleeves and a spray sock. It is critical to avoid any conditions that may cause a fire. Avoid open flames, pilot lights, sparks, heating elements, cigarettes, or any and all possible sources of ignition.

PREPARATION, STORAGE, and CLEAN UP

STIRRING and MIXING

  • Do not open and stir Rust Bullet when the temperature is below the dew point.
  • Rust Bullet is a single-component material. It is not necessary to mix "part A with part B"; however, Rust Bullet should be stirred thoroughly for at least 2 minutes or until completely uniform (avoid whipping air into product). Shaking the container of Rust Bullet prior to application may cause the formation of bubbles in the finish of the coating.
  • Rust Bullet products that have been sitting for six months or longer may develop settling. Follow the same stirring instructions, but increase the stir time and be sure to break up any clumps on the bottom of the container, if any.
  • The exact balance of viscosity, solvent, and active ingredients must be maintained; therefore, Rust Bullet must not be thinned. Thinning or adding any other product to Rust Bullet will compromise the performance and quality of the finished product.

PRODUCT STORAGE and HANDLING

  • Care should be taken to ensure that new unopened containers or left-over partial containers are kept sealed. A plastic polyethylene film may be laid on top of remaining material to displace as much air as possible.
  • Rust Bullet is moisture sensitive; limit the time the container is opened. During application, pour out the portion you will use in approximately one hour and reseal the lid as soon as possible. Immediately wipe clean any Rust Bullet from the rim of the container and reseal. This should be done every time you use Rust Bullet and in between coats. Never pour back into the original container any Rust Bullet that has been exposed to the outside air for any length of time because it will destroy the remaining Rust Bullet.
  • The shelf life of Rust Bullet is approximately two years for unopened containers and approximately three to four months for containers that have been opened. Product storage temperature range is 33°F to 120°F. Rust Bullet is a specialized moisture sensitive product; containers that have been opened should be used within in a few months for proper coating performance.

CLEAN UP TIPS

  • Use Xylene, Toluene, or MEK. Do not substitute any other solvent. Do not make assumptions about other cleanup solvents without consulting Rust Bullet Customer Support. Even a very small contamination of Rust Bullet with alcohol or other hydroxyl-containing solvents can destroy the moisture-cure reaction partly or entirely without any indication or jelling.
  • Spills must be cleaned up immediately or the product will harden and become next to impossible to remove. Avoid getting on body, clothes, or any surface not intended to be coated. Rust Bullet is permanent; after curing, Rust Bullet can only be removed with rigorous abrasive action. Clean up fresh, uncured Rust Bullet immediately by using Xylene, Toluene, or MEK, following the solvent manufacturer's directions. Washing with soap and water may work, if done immediately.
  • Application equipment must be cleaned immediately after use to avoid damage. Thoroughly flush equipment clean. Do not leave residue as it will harden and become insoluble in solvent. Clean equipment as you would with any typical two component catalyzed coating. Always clean brush or roller thoroughly. Dunking dirty equipment in solvent will not prevent the coating from curing overnight.

IMPORTANT POINTS TO REMEMBER WHEN USING RUST BULLET PRODUCTS

  • Never allow sweat, rain, or mist to fall into Rust Bullet.
  • Never over stir, entrap, or whip air into Rust Bullet.
  • Never allow lacquer thinner, vinyl thinner, epoxy solvent, or any alcohol or unapproved solvent to enter Rust Bullet.
  • For clean-up use only clean Xylene, Toluene, or MEK.
  • Never neglect to purge all paints, moisture, or debris from equipment before spraying Rust Bullet.
  • Never apply Rust Bullet while raining or under threat of rain.
  • Applying a topcoat over Rust Bullet is not necessary. If one is desired, wait 24 to 48 hours after the application of the final coat of Rust Bullet.
  • Only pour out what you intend to use in one hour and replace the lid immediately.
  • Never pour back into the original container any Rust Bullet that has been exposed to outside air for any length of time as this will destroy the remaining Rust Bullet.
  • Care should be taken to ensure that new unopened containers or left-over partial containers are kept sealed. Heavy Duty Plastic Wrap can be placed over the top of the remaining coating with the excess plastic exceeding beyond the rim of the container. This will displace as much air as possible from the remaining coating and will help prevent the lid from permanently sealing closed.