Rust Converters: Complete UK Guide

Rust converters are an essential tool in the fight against vehicle corrosion, offering a chemical solution that transforms existing rust into a stable compound that can be painted. This guide explores how these products work, best application practices, and reviews the top rust converters available in the UK market.

What Are Rust Converters?

Rust converters are chemical treatments designed to react with iron oxide (rust) and convert it into a stable, inert compound that prevents further corrosion. Unlike rust removers that dissolve rust entirely, converters transform the rust into a protective coating that serves as a primer for paint application. This makes them ideal for treating areas where complete rust removal isn't practical.

In the UK's damp climate, rust converters have become increasingly popular for vehicle maintenance, especially for treating areas like wheel arches, floor pans, and chassis components where rust frequently develops due to exposure to road salt and moisture.

How Rust Converters Work

Most commercial rust converters contain two primary active ingredients:

• Tannic acid or similar organic acids that react with iron oxide to form iron tannate, a stable blue-black compound
• Polymer resins that create a protective coating over the converted rust surface

When applied to a rusted surface, the rust converter initiates a chemical reaction that converts iron oxide (Fe₂O₃) into magnetite (Fe₃O₄), a more stable form of iron oxide. This conversion process changes the rust from its familiar reddish-brown color to a dark blue-black finish, indicating the chemical transformation has occurred.

The Science Behind the Conversion

When tannic acid contacts iron oxide, it creates iron tannate through a complex reaction. This compound is significantly more stable than rust and forms a protective barrier on the metal surface. The polymer component then creates an additional protective layer that seals the converted rust from oxygen and moisture, preventing further corrosion and providing a suitable surface for primer and paint application.

Application Tips for Best Results

Proper application is crucial for rust converters to work effectively. Follow these guidelines to achieve optimal results when treating rusted vehicle surfaces:

Surface Preparation

• Remove loose rust, scale, and flaking paint with a wire brush or sandpaper
• Clean the surface thoroughly to remove dirt, grease, and oil
• Ensure the surface is completely dry unless the product specifically states otherwise
• Mask off areas not requiring treatment to prevent accidental application
• Work in a well-ventilated area and wear appropriate protective equipment

Application Method

• Apply the converter with a brush, roller, or spray depending on the product formulation
• Ensure complete coverage of all rusted areas
• Apply in thin, even coats rather than thick layers
• Allow each coat to dry completely before applying additional coats
• Apply a minimum of two coats for optimal protection

Top UK Rust Converters

The UK market offers several high-quality rust converters with proven track records. Here are five of the most effective products available:

1. Kurust by Hammerite

A popular UK-made rust converter that transforms rust into a sound base for painting in just 15-30 minutes. It features a convenient brush-on application and a color-change formula that turns from blue to black when conversion is complete.

Key Features:

• Fast-acting formula (15-30 minutes conversion time)
• Color-changing indicator
• Water-based formula for easy cleanup
• No need to remove all rust before application
• Made in the UK specifically for British climate conditions

2. Bilt Hamber Hydrate 80

A professional-grade rust converter developed in Essex, UK, specifically for the British climate. Hydrate 80 chemically converts rust into a stable iron phosphate compound and leaves a zinc phosphate coating for additional protection.

Key Features:

• Professional-grade formula
• Forms zinc phosphate coating for extended protection
• Excellent for chassis and underbody treatment
• Can be left as a standalone treatment or painted over
• Low VOC formulation

3. Rust-Oleum Rust Reformer

A robust rust converter that transforms rust into a paintable surface with a single application. It forms a tight bond that seals out moisture and prevents future rust formation.

Key Features:

• Any-angle spray application for hard-to-reach areas
• Dries to touch in 20-40 minutes
• Black finish that can be primed and painted
• Oil-based formula for superior adhesion
• Covers approximately 0.9m² per can

4. Jenolite Rust Converter

A long-established British product that converts rust into a stable black compound and provides a protective polymer coating. Jenolite has been manufactured in the UK since 1939 and is formulated specifically for the British climate.

Key Features:

• Available in brush-on and spray formulations
• Works in hard-to-reach areas
• No need to remove all rust before application
• Creates a water-resistant barrier
• Traditional British product with decades of proven performance

5. Fertan Rust Converter

A German-engineered product popular in the UK restoration community. Fertan converts rust into iron tannate and provides exceptional long-term protection, particularly for classic car restoration projects.

Key Features:

• Professional-grade formula
• Water-based, non-toxic formulation
• Converts rust into stable iron tannate
• Highly regarded in the classic car restoration community
• Can be used on intricate components like fuel tanks

Product Comparison

Conclusion

Rust converters offer a practical solution for treating rust on vehicles, particularly in the UK's damp climate where rust is a common problem. While they don't replace proper rust repair for structural components, they provide an effective way to treat and stabilize surface rust and prevent its spread.

When choosing a rust converter, consider the specific application, the severity of the rust, and whether you plan to paint over the treated area. For small spot treatments, products like Kurust offer convenience and speed, while restoration projects may benefit from professional-grade products like Fertan or Bilt Hamber Hydrate 80.

Remember that rust conversion is just one part of a comprehensive rust treatment strategy. For long-term protection, converted areas should be properly sealed with appropriate primers and topcoats to prevent moisture from reaching the metal surface.