How to Paint a Rusted Metal File Cabinet

Painting a rusted metal file cabinet can seem like a daunting task, but with some preparation and the right materials, it can be accomplished by a DIYer. Here is a step-by-step guide on how to properly paint a rusted metal file cabinet and achieve a smooth, professional-looking finish.

Assessing the Damage and Prepping the Surface

The first step is to thoroughly inspect the cabinet for areas of rust and damage. Determine how severe the rust is and how much needs to be addressed before painting.

• Use a wire brush to remove any loose flakes or scales of rust. This gets rid of the overt signs of rust and allows the paint to adhere better.
• For moderate to severe rust, use sandpaper to scrub the area smooth. Start with a coarse grit like 80 and work up to a fine grit around 220 for the final sanding.
• Clean the sanded surface to remove any dust or debris. Tack cloths work well for picking up metal particles.
• Apply a rust-inhibiting primer like Rust-Oleum® Rusty Metal Primer before painting. This will prevent future rust from forming under the new paint.
• Fill any pits, holes or cracks with metal filler designed for rusty surfaces. Allow ample drying time as specified on the product label before sanding smooth.

Properly prepping the rusted surface is crucial for getting the paint to cling to the metal and last. Rushing this step can lead to peeling or flaking paint down the road.

Choosing the Right Paint

For painting over rusty metal, specific types of paint are required:

• Rust-Inhibiting Enamel Paint – Contains rust fighting ingredients to prevent further rust from forming under the paint. High gloss enamel versions provide added protection.
• Direct-to-Metal (DTM) Paint – Formulated to bond tightly to metals without a primer. Often has rust-inhibiting properties as well.
• Hammered Paint – Has a textured, hammered finish that hides imperfections like scratches or uneven surfaces.
• Outdoor Paint – Formulated to withstand outdoor elements like rain, snow and UV rays. Ideal for patio furniture or outdoor lockers.

Avoid standard latex wall paints as they lack the adhesion and rust-fighting abilities needed for metal surfaces prone to rust.

Painting the Cabinet

Follow these steps when painting:

• Apply Primer – Use a dedicated metal or rust-inhibiting primer first to maximize paint adhesion. Fully cover all surfaces evenly.
• Add Top Coat(s) – For a smooth finish, apply two coats of enamel, DTM or hammered paint, allowing proper dry time between coats.
• Replace Hardware – Remove cabinet hardware like hinges and handles during painting. Reattach with new hardware after for an updated look.
• Clear Coat (Optional) – A clear coat adds an extra layer of protection on top of colored paint. Ideal for high-traffic surfaces.
• Check Coverage – Inspect painted area to ensure you’ve adequately covered all the rusty areas. Touch up as needed.

Proper primer and paint selection, combined with adequate surface prep, will provide long-lasting, professional results.

Maintaining the Painted Finish

To get the most longevity out of a painted metal filing cabinet, follow these maintenance tips:

• Keep the cabinet out of direct sunlight to avoid premature fading and wear.
• Avoid placing wet or damp items directly on the painted surface.
• Quickly clean up any spills to prevent possible paint staining.
• Reapply clear coat every year or two for added protection.
• At first signs of new rust peeking through, sand and spot paint to stop rust spread.
• When paint eventually fades or chips after years of use, sand and repaint following the steps above.

With proper prep and paint application, you can enjoy a beautifully refreshed filing cabinet free of rust. Follow yearly maintenance and touch-up as needed to keep it looking pristine.

Frequently Asked Questions

What kind of sander should I use to remove rust?

Use a random orbital sander with variable speed settings. Start with 60-80 grit pads for heavy rust removal and work up to 220 grit for smooth final sanding before priming and painting.

What should I use if the rust is severe and pitted?

For heavy rust with pits and holes, use a rust converter product first to stabilize the rust before priming and painting. Rust converters chemically convert rust into an inert protective barrier.

How long does it take for primer and paint to fully dry and cure?

Most primers and paints take 1-2 hours to dry to the touch but may take up to 30 days to fully cure and reach maximum hardness and durability. Check your product labels for specific dry/cure times.

Should I use brush, roller or sprayer to apply the paint?

For metal surfaces, airless sprayers allow you to most evenly apply primer and paint. But brushes and rollers can also be used with high quality results. Ensure full, even coverage with whichever method you use.

How do I get rid of rust inside the file cabinet?

For interior rust, thoroughly scrub with a wire brush or sandpaper to get rid of loose rust. Apply a specialty rust converter product to convert any remaining rust into an inert layer. Then prime and paint the interior as normal.

Conclusion

Painting over rust on a classic metal filing cabinet brings it back to life with a fresh new look. While the process takes some work, the results are well worth it. Following the steps for proper preparation, painting and ongoing maintenance will keep your cabinet looking renewed and rust-free for years of stylish storage.