Rust is the natural enemy of any metal surface. Once it takes hold, it’s extremely difficult to remove completely. That’s why a product like Corroseal 1 Gal Rust Converter Primer can be invaluable for combatting and preventing rust.

As a high-performance rust converter, Corroseal works by converting existing rust into a black polymeric coating while also preventing further rust from developing. With the ability to cover up to 500 sq ft, Corroseal 1 Gal provides an economical and effective rust treatment solution for metal surfaces both indoors and out.

If you’re looking to buy Corroseal Rust Converter Primer, this detailed buying guide will provide you with everything you need to know, from how it works to where to purchase it and much more.

What is Corroseal Rust Converter Used For?

Corroseal is designed to convert rust and prevent further corrosion. It works on rusted iron and steel surfaces, including automobiles, railings, equipment, storage tanks, metal rooftops, and more.

While abrasive blasting is the most thorough way to remove rust, it isn’t always practical or accessible. Corroseal provides an easier, single-step alternative. Rather than removing rust, it transforms the rust into a hard polymeric coating right on the surface.

Corroseal can be used for both interior and exterior rust problems. Its water-based formula is safe for application on items around the house, farm equipment, trailers, vehicles, and any other rusted metal surface that needs protecting.

How Does Corroseal Rust Converter Work?

The active ingredient in Corroseal is tannic acid, an organic compound derived from plants. When applied to rusted metal, the tannic acid undergoes a chemical reaction with the rust (iron oxide).

This reaction converts the rust into iron tannate, a dark-colored stable compound. Unlike rust, iron tannate is an inert, protective finish that halts the corrosion process and prevents further rust from developing.

In addition to the tannic acid, Corroseal contains a water-based acrylic polymer coating. This coating seals and adheres to the converted rust layer, providing a smooth, finished surface.

So in summary:

• Tannic acid converts rust into iron tannate
• Polymer coating seals and binds to converted rust layer
• Rust is transformed into a hardened, protected finish

This chemical conversion process allows Corroseal to stop rust in its tracks while also saving you from having to completely remove rust manually.

What Surfaces Can Corroseal Be Used On?

Corroseal is formulated to work on iron and steel surfaces. This includes:

• Automobiles: Corroseal is safe for use on body panels, bumpers, wheel wells, frames, and other rusted areas on cars, trucks, trailers, and RVs.
• Equipment: Farm equipment, machinery, trailers, railings, generators, and any other equipment with rusted metal components.
• Structures: Metal roofs, gutters, pipes, structural supports, wrought iron fences, and other external building structures prone to rust.
• Household: Cast iron cookware, antiques, old tools, bicycles, and other household items made of iron or steel.
• Outdoorfurniture: Cast iron or steel patio sets, benches, gates, statues, and decorative ironwork.

While mainly intended for iron and steel, Corroseal can also be used on other metals like copper, brass, chrome, and aluminum to prevent tarnish and corrosion.

It’s important to note that Corroseal cannot be used on galvanized steel. The zinc in galvanized steel prevents the product from penetrating and working effectively.

How to Apply Corroseal Rust Converter Primer

Applying Corroseal is a quick and simple process. Here are the step-by-step instructions:

Step 1: Prepare Surface

It’s important to properly prepare the rusted surface before applying Corroseal:

• Remove loose rust and flaking paint with a wire brush or sandpaper.
• Clean the surface of grease, oil and dirt to allow Corroseal to adhere.
• Lightly sand glossy surfaces to improve adhesion.
• Remove salt, chemical deposits and water with appropriate cleaners if present.
• Allow surface to fully dry.

Proper preparation will allow Corroseal to penetrate for best results.

Step 2: Apply Corroseal

Use a brush, roller or airless sprayer to generously apply an even coat of Corroseal over the prepared rust surface.

• Brush: Use a natural bristle brush for small surfaces and in hard-to-reach spots.
• Roller: A roller with a 1/4″ nap is ideal for quickly coating large flat areas.
• Sprayer: Airless sprayer with .017-.019 tip allows efficient application on big projects.

Apply in temperatures between 50-90°F. Corroseal will dry slower in cooler temperatures.

Step 3: Allow to Dry

Corroseal dries to the touch in 30 minutes. The conversion process continues for 24-48 hours.

• Allow Corroseal to dry for a minimum of 24 hours before applying other coatings.
• After drying, check for and touch up any missed spots.

Proper drying is essential for Corroseal to completely convert rust.

Step 4: Apply Finish Coating (Optional)

While not required, Corroseal can be topcoated for added protection and enhanced aesthetics:

• For best adhesion, apply finish coatings within 2-3 days of application.
• Suitable topcoat options include latex, oil-based paints, powder coating or automotive paint.
• The converted rust surface provides excellent adhesion for finish coatings.

And that’s it! Following those simple steps will allow you to effectively and easily treat rust with Corroseal.

Where Can I Buy Corroseal 1 Gal Rust Converter Primer?

Corroseal is sold at many home improvement stores and retailers. Here are some of the best places to find it:

• Home Depot: Corroseal 1 Gal is stocked at most Home Depot stores and on HomeDepot.com.
• Lowe’s: Available at Lowe’s locations and Lowe’s online store. Often in stock and competitively priced.
• Amazon: Sold by Amazon directly and various third-party sellers with quick shipping.
• Walmart: Can be purchased online on Walmart.com and sometimes available in auto departments of stores.
• ACE Hardware: Local ACE Hardware stores typically carry Corroseal or can special order it.
• True Value Hardware: Check True Value for availability of the 1 Gal container.
• Auto Parts Stores: Sold at many auto parts retailers like O’Reilly Auto Parts, Advance Auto Parts, AutoZone.

For the best price, selection and availability, larger retailers like Home Depot and Lowe’s are your best bet for buying Corroseal. Amazon also offers quick shipping and convenience.

What is the Price of Corroseal 1 Gal Rust Converter Primer?

On average, you can expect to pay around $25-35 for a 1 gallon container of Corroseal Rust Converter Primer.

Here are some typical pricing examples:

• Home Depot: $27.98 per gallon
• Lowe’s: $29.98 per gallon
• Amazon: $28.99 per gallon
• Walmart: $25.97 per gallon

Larger quart and pint sizes are also available:

• Quart: $18-22
• Pint: $12-15

For the best value, the 1 gallon size is recommended for larger jobs and maximum coverage. The smaller containers can be useful for small projects or testing on a portion of the surface first.

Pro tip: Check for any available coupons or promotions from retailers before purchasing. Bulk and case ordering also sometimes offers a discounted per gallon price on Corroseal.

How Many Square Feet Does Corroseal 1 Gal Cover?

One gallon of Corroseal Rust Converter Primer will cover approximately 500 square feet of rusted metal surface area.

This estimated coverage rate can vary depending on:

• Surface Texture: Smoother surfaces allow for greater coverage than uneven or porous rusty areas.
• Coat Thickness: Applying in a thick single coat will result in less total coverage.
• Rust Extent: Severely rusted surfaces with excessive flaking may necessitate more product.
• Application Method: More overspray occurs with spraying compared to brushing or rolling.
• Number of Coats: Additional coats will increase total product usage.

For reference, Corroseal dries to a thickness of approximately 2-4 mils. Take the surface area and type into account when determining how much Corroseal to purchase for your particular rust treatment project.

How Long Does Corroseal Take to Dry?

One of the advantages of Corroseal is its relatively quick drying time:

• It will dry to the touch in about 30 minutes at room temperature.
• The full curing time is 24-48 hours after application.
• Corroseal will take longer to dry and cure in cooler temperatures below 50°F.

To allow Corroseal to fully convert the rust and become an inert coating, it’s essential to let it dry for at least 24 hours before use or applying any topcoats. This will permit the chemical conversion process to properly complete.

Drying times will depend on environmental conditions and air circulation. Fans can help accelerate drying if needed.

Is Corroseal 1 Gal Rust Converter Primer Safe to Use?

When used as directed, Corroseal 1 Gal Rust Converter Primer is considered safe and non-toxic for DIYers and professionals. Key facts about its safety:

• Water-Based Formula: Uses a water-based acrylic polymer carrier for low odor and easy cleanup.
• Low VOC: Contains less than 10% Volatile Organic Compounds making it environmentally friendly.
• Non-Flammable: Does not contain any flammable solvents for safer application.
• Minimal Exposure Risk: Low potential for skin irritation or inhalation issues during application.

Proper safety precautions are still recommended including ventilation, gloves, eye protection and avoiding prolonged skin contact or ingestion. It is also not recommended for potable water systems.

Overall, Corroseal offers rust treatment and prevention abilities comparable or better than many more hazardous solvent-based options for a much lower toxicity risk.

What are the Ingredients in Corroseal?

Corroseal consists of two key active ingredients:

• Tannic Acid: Derived from natural plant sources, tannic acid reacts with iron oxide in rust to convert it into iron tannate.
• Acrylic Polymer Emulsion: Water-based acrylic coating that forms a protective seal over the converted rust.

It also contains small amounts of:

• Propylene glycol to improve flow and driability.
• Ammonia to help with corrosion resistance.
• Detergents for adhesion and surface wetting abilities.

The exact percentages are proprietary, but Corroseal is notably free of chromates, lead, mercury, and other hazardous compounds found in some converters.

How to Prepare a Surface for Corroseal Application

Proper surface prep is key for Corroseal to work most effectively. Here are some tips:

• Remove Loose Rust: Use a wire brush or sandpaper to get rid of any loose, flaking or blistered rust.
• Clean: Wipe down the surface with a degreaser to remove dirt, grease, oil and salt deposits. Rinse thoroughly.
• Dry Surface: Allow surface to fully dry before applying Corroseal. Trapped moisture will hinder results.
• Lightly Abrasion: For smooth/glossy areas, lightly sanding will “profile” the surface for better adhesion.
• Test: Always test Corroseal on a small area first to ensure proper application and results.

Taking the time to correctly prepare the surface will allow Corroseal to penetrate, convert rust and polymerize properly.

Can Corroseal be Painted Over?

Yes, Corroseal Rust Converter Primer is fully compatible with being topcoated with both latex and oil-based paints.

In fact, adding a finish coat of paint is recommended for improved aesthetics and added protection.

The key is to ensure Corroseal has adequately cured first:

• Allow Corroseal to dry and cure for 24-48 hours before painting over it.
• Apply finish coating within 2-3 days for optimal adhesion.

The converted rust surface will provide excellent adhesion for the topcoat. Make sure to follow the paint manufacturer’s application guidelines.

With the proper dry times, Corroseal provides a great base coat and primer to permanently stop rust and prevent bleed-through on painted metal.

What are the Reviews for Corroseal 1 Gal Rust Converter Primer?

With decades of proven results, Corroseal Rust Converter Primer earns high marks in reviews from both professionals and DIYers:

• Home Depot: 4.7 out of 5 stars with over 450 reviews praising its ease of use and rust conversion abilities.
• Lowe’s: Consistently 5 stars from buyers confirming it stops rust very effectively.
• Amazon: Earns 4.5 stars in over 2,000 reviews for being easy to apply and “working like magic” on rust.
• Trustpilot: Overall rating of “Excellent” based on 100+ reviews. Many mention it worked when other products failed.

The vast majority of reviews confirm Corroseal rapidly stops rust in its tracks while going on easily and drying quickly. Satisfied buyers range from auto restorers to homeowners with rusty railings and roofs. It’s gained a reputation as an effective and affordable rust converter.

Common compliments are that it is easy to apply, dries quickly, stops rust permanently and provides great value. Most negative feedback relates to user error rather than issues with the product itself.

How to Store Corroseal Properly

To maintain effectiveness and shelf life, proper storage of Corroseal Rust Converter Primer is recommended:

• Keep container tightly sealed when not in use.
• Store in a dry location away from moisture.
• Avoid freezing temperatures or intense heat over 100°F.
• Place on a raised surface off bare concrete.
• Wipe clean and replace lid firmly after each use.

When stored correctly in a controlled environment, Corroseal has a shelf life of 2-3 years from the manufacturing date.

Always inspect Corroseal prior to use and stir thoroughly. If stored too long it may require a light sanding to refresh the surface. Proper storage will maintain maximum rust converting potency.

Does Corroseal Require Additional Primer?

A primary benefit of Corroseal is that it functions as both a rust converter and a primer in one single product.

The converted rust surface it leaves behind serves as its own protective primer layer. So no, additional primer is not required before painting over it.

In most cases Corroseal can be applied directly to prepared rust surfaces. The exceptions would be:

• Severely pitted or porous surfaces may benefit from a filler primer first to smooth.
• Galvanized steel requires a dedicated etch primer.
• If painting over glossy/non-porous metals, a primer for adhesion may be preferred.

But for general rusty iron and steel, Corroseal eliminates the need for any additional primers or undercoats. It saves time and money in repair projects.

How Effective is Corroseal 1 Gal Rust Converter Primer?

With proper application, Corroseal Rust Converter Primer is extremely effective at stopping existing rust and preventing further corrosion.

Here are some of its key benefits supported by customer reviews and years of proven performance:

• Stops Rust Quickly: Converts rust in minutes and prevents new rust from forming.
• Easy Single-Step Application: Goes on easily by brush, roller or sprayer. No mixing required.
• Excellent Adhesion: Bonds tightly to steel, iron, aluminum and other metals.
• Compatible Topcoats: Provides ideal base for paints and powder coating.
• Long-Lasting Results: Permanently stops rust without future bleed-through.
• Economical: Large 1 gal size covers approx. 500 sq ft for a lower cost per sq ft compared to similar options.
• Low Odor and VOC: Much less odor and fumes than solvent-based rust converters.

For a convenient and highly effective rust treatment, Corroseal delivers exceptional value and results. Many reviewers report it worked better than other more expensive products.

Can Corroseal be Used on Vehicles?

Yes, Corroseal Rust Converter Primer is safe and commonly used for automotive rust repair.

It’s effective on surfaces like:

• Frames, bumpers, undercarriage components
• Fenders, rocker panels, wheel wells
• Trunk areas, door bottoms, hoods
• Hitches, trailers, flatbed truck beds

Corroseal stops rust and primes surfaces for automotive paint finishes like enamels and urethanes. It saves time over sandblasting and works well in small DIY doses or for large professional shops.

For best results on vehicles:

• Wash and degrease areas thoroughly first
• Sand glossy paint around rust spots
• Apply in thin coats, drying between coats
• Allow proper drying time before painting

Corroseal provides an easy and affordable way to stop automotive rust damage. Reviewers consistently praise the results and value compared to dealership or professional body shop repairs.

What is the Shelf Life of Corroseal?

When properly stored, Corroseal Rust Converter Primer has a shelf life of 2 to 3 years from the date of manufacture.

The shelf life assumes it has been kept in acceptable storage conditions:

• Stored at temperatures between 40°F and 100°F
• Kept in sealed container safe from moisture
• Not exposed to direct sunlight or freezing temperatures

The shelf life refers to the product maintaining full potency and maximum rust conversion abilities.

Prior to application, always inspect Corroseal for signs of:

• Separation, inconsistent texture or clumping
• Crystallization or hard caking around the rim
• Color changes or strange odor

As it ages, stirring or mild sanding may help restore Corroseal’s consistency and performance. But once beyond its usable shelf life, it should be discarded and replaced.

How to Clean Up After Using Corroseal

One advantage of Corroseal is that clean up is relatively quick and easy compared to other rust converters:

• While still wet, rinse tools/overspray with warm soapy water. Rinse thoroughly.
• Dried on drips or spills can be removed with scouring pad and ammonia-based cleaner.
• Mineral spirits can help remove dried residue but test first for paint compatibility.
• Avoid skin contact by wearing gloves and washing any areas immediately with soap and water.

Pro tip: Line surrounding surfaces with plastic sheeting when applying Corroseal to prevent drips and overspray.

Thanks to its water-based formula, Corroseal cleans up simply with mild detergents. Prompt cleanup while still wet also reduces effort. Follow proper handling procedures to prevent skin/eye irritation.

What are Common Issues with Corroseal?

When used correctly, Corroseal performs extremely well. However, there are some potential issues to be aware of:

• Surface Prep: Failing to properly prep surface can impede results. Ensure rust is removed, cleaned and dried.
• Application: Brush streaking or thick coats can lead to drying issues. Apply evenly at recommended thickness.
• Insufficient Drying: Only allowing 10-15 minutes to dry rather than the full 24-48 hours prevents proper rust conversion.
• Topcoating Too Soon: Painting over Corroseal before it has fully dried/cured may lead to poor adhesion or lifting.
• Old Product: Corroseal that has been left opened or stored incorrectly can lose effectiveness. Always seal and store properly.
• Freezing Temps: Allowing Corroseal to freeze while wet will ruin it. Store above 40°F.

With proper usage following the manufacturer’s recommendations, Corroseal provides excellent rust protection. It’s worth taking the time to use it correctly.

In Summary

I hope this comprehensive buying guide provides you with all the key facts about Corroseal 1 Gal Rust Converter Primer. It can transform heavily rusted metal into a protected, paintable surface through an innovative chemical conversion process.

With the ability to cover up to 500 sq ft, Corroseal offers outstanding value for permanently stopping rust over large areas, both indoors and out. Just be sure to properly prepare surfaces, apply appropriately, and allow adequate drying time.

Available at most home centers, hardware stores and auto parts outlets, Corroseal is a proven and highly-reviewed rust treatment solution for DIYers and pros alike. Given how difficult and expensive fully removing rust can be, Corroseal is an easy and affordable way to stop existing rust and prevent future damage.