How to Refinish Rusted Old Metal Cabinets

Refinishing old metal cabinets that have rusted can seem like a daunting task, but with some elbow grease and the right techniques and products, it is very doable as a DIY project. Breathing new life into worn, rusted metal cabinets in your kitchen, bathroom, laundry room or elsewhere not only improves aesthetics but also functionality. Follow this comprehensive guide to learn how to refinish rusted old metal cabinets from start to finish.

Assessing the Cabinets and Planning the Project

Before you begin refinishing, take time to closely inspect the metal cabinets and develop a plan of attack.

Evaluate the Overall Condition

Carefully examine the cabinets for the severity of rust, level of previous paint or coatings, dents, chips and other damage. Make notes on the problem areas so you can address them properly during the process.

• Level of rust: Is it surface rust that can just be scrubbed and primed or deeply pitted rust that requires filling?
• Existing paint/coatings: Will the original finish need to be completely removed or can it be lightly sanded and built upon?
• Dents and chips: Can they be hammered out and filled or do any pieces need replacing?
• Other damage: Is there water damage, missing hinges, drawer issues?

Choose Your Refinishing Approach

Once you’ve assessed the condition, decide if you want to:

• Strip everything and start fresh: This is the most work but allows full rust remediation and new finish.
• Lightly sand and recoat: Quicker but won’t address serious rust.
• Spot treat problem areas: For cabinets in generally good shape with just some problem spots.

Set a Budget

Refinishing cabinets yourself costs a fraction compared to new cabinet installation. Still, factor in expenses for supplies like:

• Paints, primers, finishes
• Sandpaper, sanding blocks
• Chemical strippers, degreasers
• Fillers, putty
• Rags, paintbrushes, rollers
• Safety gear

Gather Materials and Supplies

Once you have a plan and budget, purchase all the necessary supplies before starting. This includes:

• Paints and coatings: For metal, high-quality oil or alkyd enamels work best. Choose latex if ease of cleanup and low odor is preferred.
• Primers: Adheres paints to glossy or slick surfaces like metal. Etching primers help grasp rusty areas.
• Rust removers: Look for phosphoric acid-based and biodegradable gels and sprays.
• Degreasers: Remove grime and prep the surface. Avoid harsh solvents.
• Sandpaper: Extra coarse to smooth out scratches and rust pits. Finer grits sand between coats.
• Rags, brushes, rollers: For applying removers, primers and paints.
• Fillers and putty: For smoothing dents, holes and pits in metal.
• Safety gear: Gloves, goggles, masks to protect yourself.

Clean Surfaces

Before starting work, remove cabinet doors, drawers and hardware and clean all surfaces very well with a degreasing solution. This helps remove grease, oils and dirt so primers and paints properly adhere.

Protect Surrounding Areas

Cover nearby walls, floors, countertops and other surfaces with plastic drop cloths. This keeps them protected from drips, spills and splatters. Use painter’s tape for clean borders.

Removing Rust From Metal Cabinets

Prepping metal cabinets to remove rust is crucial for a long-lasting finish. Here are some effective methods.

Use a Chemical Rust Remover

Phosphoric acid-based gels are ideal for converting rust into an inert black primer coat. This stops rust in its tracks while prepping for paint.

Follow these steps for rust removal:

1. Wear protective gear like gloves, goggles and mask. Work in a well-ventilated area.
2. Apply a thick layer of the gel to rusted areas according to product directions. Avoid contact with skin and eyes.
3. Let it sit for 15-30 minutes until bubbling stops. Scrub with a stiff wire brush.
4. Wipe clean with water and rags. Rinse thoroughly.
5. Allow to fully dry. Sand any remaining rust spots with extra coarse sandpaper.
6. Apply a rust-inhibiting primer immediately so rust doesn’t continue developing.

Sand Away Surface Rust

For light surface rust, scraping and sanding may be sufficient.

• Use an abrasive sponge or extra coarse 100-150 grit sandpaper. Rub rust spots vigorously until completely gone.
• Be sure to wear a safety mask so you don’t inhale rust particles. Thoroughly wipe clean all sanding residue.
• Apply primer soon after to prevent further rust. Fill any pits or depressions with metal filler before priming.

Make a Vinegar Rust Remover

For an eco-friendly rust remover, white vinegar is acidic enough to dissolve light surface rust.

• In a spray bottle, mix 2 parts white vinegar with 1 part water. Spray liberally over rusted areas and let sit 15-30 minutes.
• Scrub with steel wool and wipe clean. Repeat for stubborn spots. Rinse surfaces well.
• Dry thoroughly before priming and painting. The vinegar smell will fade as it dries.

Use Naval Jelly

This phosphoric acid-based rust remover comes in a thick gel. Brush a layer onto affected areas, wait 15-30 minutes, then rinse clean and scrub with steel wool. Wear gloves and ventilation is key.

Sandblast Rust for Deep Pitting

For severe, deep rust pitting, sandblasting is the most effective way to remove all traces of rust and create a smooth surface for painting. Rent a sandblaster and compressor or hire a professional if needed.

Prepping and Priming Cabinets

After addressing any rust issues, properly prep and prime the metal to ensure paint adheres well.

Wash and Degrease

Give all cabinet surfaces a thorough wash with an all-purpose cleaner or degreasing solution like trisodium phosphate (TSP). This removes built-up grease, dirt and residue.

Sand Glossy Surfaces

Use 150-220 grit sandpaper to scuff up any glossy cabinet surfaces. This helps primers and paints bond tightly.

Spot Fill Dents and Holes

Use a metal filler paste to fill any dings, scratches and holes. Let dry fully and sand smooth.

Cut and Sand Ragged Edges

To prevent rust from creeping back under new paint, sand any loose, cracked or bubbled paint edges down to create a smooth border.

Remove Doors and Hardware

All doors, drawers and hardware should be removed and painted separately for easiest access to cabinet frames.

Clean Away Dust

Tack cloth all surfaces to pick up any remaining dust or debris after sanding. This prevents speckles in the new finish.

Apply Etching Primer

For heavily rusted cabinets, a phosphoric acid-based etching primer will lock in any remaining rust and firmly grip the metal. Products like KILZ Adhesion Primer help stop recurring rust.

Use Rust-Inhibiting Primer

For lightly rusted cabinets, a rust-inhibiting primer such as Rust-Oleum stops rust and prevents future corrosion. Allow to fully dry.

Apply High-Build Primer

Adding a high-build primer like Zinsser Bulls Eye 123 levels out any remaining pits, bumps or scrapes in the metal from dents and scratches.

Painting Cabinet Frames and Doors

Follow these best practices for neatly painting cabinet frames and doors:

Work in a Dust-Free Area

Paint in a room with no airflow, outdoors or in a spray booth to prevent dust nibs in the finish.

Use a Small Roller and Brush

Use a short nap roller to quickly apply paint to large surfaces. Follow with a high-quality brushed in the direction of the metal grain.

Thin the Paint Slightly

For smooth application, thin enamel and oil-based paints 10% with the recommended solvent such as paint thinner or mineral spirits.

Apply Multiple Thin Coats

Heavily loaded brushes cause drips and brush marks. Apply multiple thin, even coats for a flat, flawless finish. Lightly sand and recoat as needed.

Use Slow, Even Strokes

Move the brush at a steady, consistent pace without stopping mid-stroke. Avoid overbrushing. Allow each coat to fully dry between applications.

Work Methodically

Paint systematically from top to bottom, side to side, maintaining a wet edge for uniform coverage.

Pay Attention to Edges

Use small trim brushes to carefully coat around hinges, lip edges and corners for an ultra-smooth painted finish.

Spray Paint Doors

For professional results, spray cabinet doors with an enamel paint using an HVLP spray system outdoors or in a spray booth. Practice first on cardboard.

Allow Proper Drying Time

Give each coat of primer and paint at least 24 hours drying time before recoating for full curing. The wait is worth the durable finish.

Applying Alternative Finishes

Painting over rusty metal cabinets is most common, but other finishes are also an option.

Use an Enamel Appliance Paint

For a durable gloss finish resistant to moisture, grease and stains, use a rust-preventing appliance epoxy formula. Available in many colors.

Consider a Tinted Polyurethane

Wiping on multiple coats of an oil-based wipe-on polyurethane provides protection with light tinting. Good for a natural metal look.

Stain and Clear Coat

For a natural metal patina, use an iron phosphate-based metallic stain followed by a matte water-based polyurethane topcoat.

Use Rust Reformer

Brush on a rust reformer like Extend to convert rust into a black primer and protect the metal beneath. No sanding required.

Try Heat-Tolerant Paint

For cabinets around ovens and grills, use a high heat enamel made for grills, wood stoves and fireplaces that can take temperatures up to 1200°F.

Consider Leaving As-Is

Rust add an industrial, vintage allure. Removing loose rust, applying a clear topcoat and leaving as-is is also an option.

Troubleshooting Problems

Even with proper prep and technique, you may encounter some common problems when refinishing metal cabinets:

Issue: Rust keeps returning after refinishing

Solution: Ensure all rust was fully removed before priming. Use etching primer on bare metal. Allow paints to fully cure before exposure to moisture. Improve kitchen ventilation.

Issue: Paint drips, runs and sags

Solution: Avoid overloading the brush. Apply thinner coats. Use slower brush strokes and a small trim brush for edges and corners.

Issue: Paint bubbles or doesn’t adhere

Solution: Confirm glossy surfaces were properly sanded for paint to grip. Make sure primers and paints are compatible. Check that degreaser residue wasn’t left behind.

Issue: Discoloration and dark streaks under paint

Solution: Rust may not have been fully removed. Use a stain-blocking primer made to cover rust stains before painting.

Issue: Flaking or peeling paint

Solution: Don’t apply paint too thickly. Allow proper drying time between coats. Sand lightly between coats for better adhesion.

Issue: Brush marks and uneven coverage

Solution: Use high-quality applicators. Thin paints appropriately. Apply finish coats slowly using parallel strokes.

Maintaining Your Refinished Metal Cabinets

Once your metal cabinets are beautifully refinished, keep them looking like new with regular care and maintenance:

• Use pan liners and shelf liners in high moisture, wear areas.
• Immediately wipe up spills, drips and condensation.
• Avoid slamming cabinet doors or overloading shelves.
• Frequently clean cabinets with a soft cloth and gentle cleaner.
• Reseal bare metal edges and corners annually with clear polyurethane.
• Watch for new rust spots and treat promptly with sanding and touch up paint.
• Clean out under sink cabinets regularly to check for leaks.
• Consider moisture-controlling inserts for problem areas like under sinks.

With the right tools, materials and techniques, refinishing worn, rusted metal cabinets can be a very DIY-friendly project that makes a huge visual impact. Properly prepped and finished cabinets not only look attractive but also are protected from recurring rust damage. Just take it step-by-step to get fantastic, long-lasting results.

Frequently Asked Questions About Refinishing Metal Cabinets

What is the best paint for refinishing old metal cabinets?

High-quality oil or alkyd enamel paints provide the toughest, most rust and moisture resistant finish. For low-odor and easy cleanup, water-based acrylic or latex paints also perform well. Match paint to the cabinet’s use, like high heat paint for around ovens.

Do I absolutely have to remove all the rust before painting?

Removing all rust down to bare metal is ideal to prevent recurring rust bleed-through. For light surface rust only, you may be able to clean, lightly sand and paint over it. But remove heavy rust or risk continued damage beneath paint.

Should I use a primer when refinishing metal cabinets?

Quality primer provides superior rust prevention, enhances paint adhesion and improves the finish look. For refinishing metal cabinets, etching and rust-inhibiting primers are highly recommended. Oil-based primers are best for bare metal.

How do I get rid of rust staining on metal cabinets?

Rust leave behind orange and brown stains even if the rust itself is removed. A high hiding, stain-blocking primer such as Kilz Adhesion Primer or Zinsser’s B-I-N Primer seals in stains so topcoat paints look clean and bright.

Is there a quick way to remove rust from metal cabinets?

Sanding takes time and elbow grease. For quicker rust removal, chemical removers with phosphoric acid convert rust and etch the surface for priming in just 20-30 minutes. Look for gels and sprays made for rust removal.

Can I use rubbing alcohol to remove rust from cabinets?

White vinegar is a better mild acid for light rust removal. Rubbing alcohol alone won’t eliminate rust. But a 50/50 rubbing alcohol and water mix helps remove rust stains after other removal methods. Rinse well and allow to fully dry.

Should I use oil or water-based polyurethane on metal cabinets?

Oil-based polyurethanes provide better protection for metal surfaces. But water-based versions dry faster and clean up easier. For best results, apply oil-based poly first followed by a few coats of water-based.

How do I paint cabinets for a smooth, professional look?

Proper prep, high-quality primer and paint plus the right application techniques prevent brush marks and uneven coverage. Sand lightly between coats and use slow, parallel brush strokes. Consider spraying cabinets for an ultra-smooth finish.

How can I improve kitchen cabinet ventilation to prevent rust?

Moisture from cooking and sinks contributes to cabinet rust. Improve airflow by opening windows when cooking. Install range hood ventilation over appliances. Make sure cabinets have adequate interior air circulation.

How soon can I use my cabinets after painting?

It’s best to avoid use for 2-3 days to allow paint to fully cure. Keep cabinet doors open during this period so the paint can dry thoroughly. Avoid contact with water or heavy contents to prevent damage to the new finish.