Epoxy over Picklexed and blasted steel

jtfx6552

Member
Continuing form the other thread, probably better it is on it's own anyway.

In the year 2001 (I kid you not) I started on my current project. At the time, I didn't know what I didn't know. I had the car (alkaline) dipped and set to doing the metal work. The dipper said they applied a "phosphating" solution, and that the car wouldn't flash rust for at least a short while.

Like all projects, the beginning went fast, my plan was to get the metal work done in 3-6 months (lol), send it to a body shop and have it primed and painted. Then I started to loose steam, ran into several times the amount of damage I thought I had. About 6 months into it, the car started to turn red.

To keep flash rust at bay, I used Picklex 20. I had no idea that it would lead to primer issues down the road, i just wanted to keep the car from rusting further while I worked on it.

About a year or two ago, I found my way to the hottrodders board and found that there is a downside to chemical rust treating.

The good points:
1) according to to the other thread, picklex is a weak phosphoric acid solution, less than 10%,
2) I haven't put any on in a long time
3) Most of the metal that was picklexed was removed anyway
4) Most new metal was ecoated and never picklexed
5) Of all the picklexed metal still left, the only exterior pieces that will still be on the car is the decklid and the top of the cowl, and the A pillars.
6) I sand blasted the most areas that were picklexed prior to priming. The areas I didn't blast were hit with a 3" 80 grit roloc disc. (I haven't done anything to the decklid or cowl top yet.)

Car has been primed on with SPI inside and out The bottom of the car, and engine compartment I plan to leave in SPI black, when I get it all smoothed out, a last coat sprayed with some reducer in it to knock down some of the sheen.

The inside of the car probably won't get top coated, except inside the trunk, and the dash section that shows.

Before I go any further, I think I need to test to make sure the acid was sufficiently neutralized. How is to best to do that? Should I spray some urethane top coat on the bottom, roll it over on the rotisserie and leave it in the sun to see what happens?

The bottom needs filler in a lot of places, should I purposely sand through, put some filler on, then later grind through it to make sure it is cured?

Should I put filler blobs on top of the epoxy in various random places to see if they stick?

Any help I appreciated. I actually had trouble sleeping over this last night. After a decade of work, I certainly don't want my paint to fall off.
 
What Barry says to do is mix up a golfball size of filler and apply it over the epoxy. After it sets up then try to pry it off. If it lifts the epoxy then the epoxy has not bonded with the metal. Be sure to give the epoxy a few days to cure. Hope this helps.
 
Guy,
You have nothing to worry about with what you just posted, we are really busy and two people short SO I will explain tonight or Saturday.
Hang tight!
Barry
 
You must be right next door to New Age blast media, who sells crushed glass for $8 per 50# bag. I haven't used it yet but everybody speaks highly of it and you don't need to wash it after blasting. So I would spend a couple of days getting the media and blasting what ever areas are questionable and reprime.
http://newageblastmedia.com/

Edit; Or maybe Barry has you covered.
 
you MUST wash after blasting. i dont care what kind of media you use.

i think you may be ok since it has been so long. acid will absorb moisture from the air and in time it will flash rust. the flash tells you it has happened.
 
JCB;20443 said:
What Barry says to do is mix up a golfball size of filler and apply it over the epoxy. After it sets up then try to pry it off. If it lifts the epoxy then the epoxy has not bonded with the metal. Be sure to give the epoxy a few days to cure. Hope this helps.

That would be a good test but you have to remember the epoxy doesn't have full bond strength untill it's completely cured and this takes a lot longer that a few days.
 
With your step by step post, you have nothing to be concerned about.
Acids Films will self neutralize, problem is we don't know when, Best guesses I have heard is 3 months to a year for a phosphoric acid.

Also next statement about the car turning color in six months or so, is nothing more then flash rust, and flash rust is a painters friend because that tells you there is nothing on the metal to protect it from rusting, so all you have to do if there is flash rust is prep, clean and paint..

Time was on your side and it worked out good.
 
What is the proper way to get rid of flash rust? Not after acid... just if the metal gets wet or if you wash it with water.
 
If you have flash rust, how do you get into the cracks and crevasse? I have some New Age Media that I will be blasting w tomorrow. What do you have to wash before primer? How do you wash without introducing or causing rust before primer? I thought that as long as your primer does not contain Acid, you were ok to use a Phosporic Acid prep product prior to Epoxy Primer?
 
Clean your blasted metal with wax and grease remover, if the rough surface snags your toweling and collects fibers just knock them loose with a clean scotchbrite and compressed air before shooting your epoxy. No acid needed.
 
Bob Hollinshead;20556 said:
Clean your blasted metal with wax and grease remover, if the rough surface snags your toweling and collects fibers just knock them loose with a clean scotchbrite and compressed air before shooting your epoxy. No acid needed.

So out of curiosity, why do some guys say to use water and wash down the surface w soap and water? That just seems counter intuitive to the whole idea of removing rust etc....
 
merbesfield;20567 said:
So out of curiosity, why do some guys say to use water and wash down the surface w soap and water? That just seems counter intuitive to the whole idea of removing rust etc....

Because it works for them, accomplishes the same cleaning result with a different product, a light rust discoloration doesn't bother some and hasn't proven to cause any problems, a water wash can sometimes show where contamination problems are, an unclean surface is just plain bad-I've seen primers fall off of blasted steel when not cleaned before priming-this happens a lot when blasting media has been recycled and or the surface had grease,oil,tar on it and the blasting hammered it into the texture and distributed it through media recycling.
 
i do it to remove the media from blasting. you will also get oil vapors from blasting. a good soap and water wash gets it clean. a small amount of flash is no problem. i wash the blow dry and epoxy .
 
Bob Hollinshead;20556 said:
Clean your blasted metal with wax and grease remover, if the rough surface snags your toweling and collects fibers just knock them loose with a clean scotchbrite and compressed air before shooting your epoxy. No acid needed.

That is essentially how I cleaned mine after blasting. Blew it off with a leaf blower while wiping. Then, since it is on a rotisserie I moved each surface to be verticle. I sprayed the crap out of it with SPI water based W&G remover out of a spray bottle until it was running down, then wiped downwards with a clean blue industrial Scotts paper towel.

I am still nervous, since this is my first time using epoxy. I think I'd feel better if I actually test the curing/adhesion.

How exactly do I do the "filler ball" test? Should they be round clumps? About how big? Scuff the epoxy with what grit before sticking the filler on? How long to I wait for it to cure?

If all goes well and it is really stuck on, how hard will it be to get off?

Alternatively can I just use filler in the spots that need it and figure adhesion problems will show on the edges when I sand the filler down and feather the edges?
 
Setup some test panels, blasted or sanded with 80, cleaned well, shoot two coats of epoxy and let it cure overnight, apply industry recommended max thickness of 1/8" of filler, let it cure for 30 days, beat the snot out of it with a hammer, bend test it, shoot it with your shotgun, scratch it, do some corrosion testing with salt water.... do comparison tests without the epoxy... do some with the picklex for comparison. Here's what you'll find: the adhesion of epoxy to properly prepped steel is better than filler to steel, the adhesion of filler to epoxy either within the re-coat window or sanded/cured is better or at a minimum as good as adhesion to steel, the bend tests will show the filler will bend more before cracking when epoxy is used because of the epoxy's better adhesion and flexibility, corrosion tests will be a real eye opener. Your picklex treated tests may show different results. You don't have to worry about adhesion problems between the filler and epoxy-when completed at the optimum time it's as good as it can get but even if applied over sanded epoxy that is cured the adhesion is still excellent.

30days cure:I only suggest this because for a true test you'll want to know the epoxy is fully cured, the same results may show at 1week, 2weeks, 3weeks but if you're after accurate test results why not make darn sure and let it set for 30 days, JMO
 
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