How to Refinish Rusted Metal Cabinets

Refinishing old, rusted metal cabinets can seem like a daunting task, but with some elbow grease and the right materials, it is very doable as a DIY project. Here are the steps for how to refinish rusted metal cabinets and restore them to their former glory.

Assessing the Damage

Before you begin, take a close look at the cabinets and assess the extent of the rust damage. Light surface rust can often be removed with some scouring and sanding, but deeper rust may require more intensive refinishing.

• Check for holes or pitting in the metal – deep crevices like this can be difficult to fully rehab.
• Look for flaking or bubbling paint around rust spots – this indicates the rust may be spreading under the paint.
• Try scraping a small area with a putty knife to see how deep the rust goes.

Getting an accurate sense of the rust depth will help determine the refinishing methods and products you’ll need.

Cleaning and Removing Rust

Thorough cleaning and rust removal are crucial first steps for refinishing.

Supplies Needed

• Rust removal product (naval jelly, vinegar, etc)
• Scouring pads
• Sandpaper (80-120 grit)
• Tack cloths
• Drop cloths

Steps

1. Remove doors and hardware if possible to simplify the process.
2. Apply a rust removal product liberally on rusted areas and allow it to sit for the recommended time per the instructions. This will help dissolve rust on the surface.
3. Scrub affected areas vigorously with scouring pads to scrape off any loose rust and flaking paint.
4. Wipe clean with tack cloths. Repeat rust removal, scrubbing and wiping until only smooth metal remains.
5. Sand remaining rust spots and roughened metal with 80-120 grit sandpaper to feather and blend the edges.
6. Thoroughly wipe sanded surfaces clean with a tack cloth before painting.

Filling Holes and Repairing Pitted Areas

Once all loose rust is removed, assess remaining damage. For metal with minor pitting, you can use auto body filler designed for metal. For larger holes and deeply pitted areas:

• Cut small pieces of sheet metal to fit over holes and pits. Affix with metal bonding adhesive and seam sealant.
• Apply thin coats of auto body filler over repairs and sand smooth.
• Use 100-220 grit sandpaper for final smoothing. Keep edges feathered.
• Wipe clean with a tack cloth when done sanding.

Priming and Painting

Supplies Needed

• Metal primer (either spray can or brush-on)
• Topcoat spray paint or brush-on enamel
• Foam brushes and roller covers if using brush-on paint
• Drop cloths

Steps

1. Cover surrounding surfaces with drop cloths. Work in a dust-free area.
2. Apply 1-2 thin, even coats of metal primer allowing proper dry time between coats.
3. Lightly sand primed surfaces with 220 grit sandpaper to ensure adhesion.
4. Clean sanded surface with a tack cloth.
5. Apply at least 2 coats of topcoat paint in the sheen of your choice, allowing full drying time between coats.
6. Allow paint to cure fully before re-hanging doors and re-installing hardware.

Maintaining Your Refinished Cabinets

To extend the life of your revitalized metal cabinets and prevent rust from recurring:

• Keep cabinets dry and promptly wipe up spills.
• Avoid hanging wet dishcloths over doors – allow doors to dry completely before closing.
• Use enamel paints for durability and rust prevention.
• Apply a fresh coat of paint every 1-2 years. Focus on the insides/undersides of doors and cabinets.
• Immediately touch up any scrapes or nicks in the paint.

With some time and effort, you can strip away years of rust and wear from old metal cabinets and make them look brand new again. Just be sure to properly prep the surface and use high-quality primers and paints meant for metal. Enjoy your updated kitchen space!

Frequently Asked Questions About Refinishing Rusted Metal Cabinets

How do I remove rust from metal cabinets?

Use a chemical rust remover like naval jelly or vinegar to dissolve surface rust. For deeper rust, scour with abrasive pads and sand thoroughly to get down to bare metal. Completely removing all rust is essential before priming and painting.

What kind of primer should I use?

A high-quality metal primer is ideal for refinishing metal cabinets. Look for primers specifically made for metal or galvanized steel that resist corrosion. Etching primers can provide extra grip on slick metal surfaces.

What type of paint works best?

For cabinets, enamels provide a durable and scratch-resistant finish. Opt for cabinet enamels or alkyd enamels in satin, semi-gloss or high gloss sheens. Outdoor paints or porch and floor enamels also work well and resist moisture.

Should I take the doors off the cabinets?

Yes, removing the doors simplifies the process and allows you to get full coverage on the cabinets and doors. Lay doors horizontally on sawhorses for easier priming and painting.

How do I treat pits and holes in the metal?

Fill larger holes and pits with metal patches, then apply auto body filler over the repairs. Sand smooth before priming. For minor pitting, primer and paint will fill small dents. Severe pitting may need professional metal work.

How long does the refinishing process take?

Plan on 2-3 full days for refinishing: Day 1 for cleaning/prep work, Day 2 for priming/filling repairs, Day 3 for painting. Additional dry time between steps is crucial, so the project may span 5 days to allow for drying if doing multiple coats.

How often should I repaint refinished cabinets?

Check for any new rust spots annually and touch up paint as needed, especially underneath doors. Every 2-3 years, apply a fresh coat of paint over the entire surface to maintain the finish and prevent rust.

Refinishing metal cabinets takes some work, but the results are worth it. With attention to proper prep, priming, painting and ongoing maintenance, your revitalized cabinets can look beautiful for years to come.