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Rust Control Primer


Product Description

RCP Rust Control Primer is your closest modern equivalent to Old Red Lead with some added advantages

Unlike a solids heavy single pack such as most cold galvanising products, or two pack products, RCP is the perfect blend of solids for application directly to corrosion. Contrary to media and press marketing techniques you need a compromise between these two attributes. Wetting out is explained in more depth here. Moving on from that article the higher the solids content of a product, the harder it is for it to wet out and follow the profile of the item you are painting correctly, however, too high a solvent content and you will not get enough physical product left on piece you are trying to protect.

RCP will wet out incredibly well using not only the correct balance of solids vs solvent, but because it is a SLOW CURE product it has more time to complete this task prior to setting to its DFT (dry film thickness). This is why RCP will consistently out perform even CIO Chassis In One (because it is a fast cure), and 2K Armour (because of its solids content) on Heavier corrosion.  Above and beyond most coatings RCP contains a pigment that takes rust in its reactive form, and over a period of around 9 months stabilises it to Magnetite.


To summarise RCP wets out extremely well, leaves a high build film behind protecting the peaks of the substrate, takes long enough to cure to be effective in searching out moisture and air, whilst using the rough profile of corrosion for adhesion, all the while stabilising what is already there without having to burn or remove it. The coating once cured is very tough, doesn't suffer from Sub surface corrosion which can spread and lead to Rust creep, does not require top coating, and remains semi flexible.


Available in :-




Good for

  • Direct to heavier firmly adherent rust
  • primer for most automotive 2 pack, and acrylic based products
  • Compatible with many synthetic products
  • Long term protection of keyed steel (corroded, or clean steel)

Suitable for

  • Harsh environments such as under vehicles, marine, or coastal environments
  • suspension components
  • Use as a two coat solution with no need to top coat (note. colour is teracotta)
  • patch repair work on vehicles such as spot corrosion repair

Poor for

  • Fast repair
  • Fast cure coating compatibility (if you want to use a fast cure top coat, you will require an extended cure period, and test patching).


  1. Remove all Loose paint, wax, and underseal using a paint remover.
  2. Provide a key for maximum adhesion (use an abrasive to achieve this)
  3. If any grease, or contamination is present remove with a suitable product such as panel wipe or contamination killer
  4. Clean down the surface using clean water and a Scotchbrite type scourer before drying.
  5. There is no requirement to remove all rust. You are looking ideally for a clean, dull surface, providing the coating something to adhere to.
  6. If applying to medium to heavy corrosion manual application by wetting out brush should be used. Apply the coating in a vigorous manner, working the coating in to the substrate. Air bubbles are likely to raise to the surface as the product is agitated and continues to wet out.
  7. Best prep is direct to the base metal, but can overcoat most other coatings. Test patches if unsure.


  1. Shake the can for two full minutes with the agitating ball active.
  2. Apply in cross coats at 90 degree angles allowing the coating to cure between coats.
  3. Coating will take 15>45 minutes hours to tack off, and around 1 day to fully harden. can be over coated with RCP once touch dry.
  4. following application if the entire aerosol is not used invert the can fully and depress the nozzle for 2>3 seconds to clear the actuator so it can be used again later. Consider an aerosol unblocker kit.
  5. Be sure to apply enough product. "Blacking" is the process of applying enough product to cover an item with colour, but not enough to protect it. Failure typically occurs within 6 months, and will result in spot rust and sub surface corrosion occurring. You are aiming for Sufficient DFT (Dry Film Thickness) to cover the piece properly.
  6. ALWAYS a minimum of two coats. Heavy corrosion up to 5 coats with the aerosol. If unsure contact us.


  1. Stir and agitate the product thoroughly prior to use using an agitator.
  2. The product can be brushed, rollered or sprayed.


  • Using a seam sealing, or turkshead brush, work the first coat in to the substrate/ metal you are looking to protect. This has the added benefit of greatly increasing the ability of the product to wet out benefiting the application in several ways.
  • After you have applied your first coat, allow it to cure for 1>2 hours typically. 
  • Apply your second coat using a large softer brush so as not to damage the first coat. The coating will tend to self-level and leave you a good finish.
  • Coating will take a few days depending on conditions to fully harden.
  • 2 coats medium corrosion. 3 for heavier corrosion.


  • We recommend you use a long handled narrow roller for application. This gives you a higher pressure of application for the roller, assisting wetting out properties, and gives you better access and control.
  • Apply the first coat using reasonable force and a slow pass with the roller. Repeat the rollering process in the same area several times if existing corrosion is present to assist wetting out and adhesion later on. Do not spread the product out so far that you reduce the amount of coating, and thus reduce the protection available.
  • Allow coating to cure semi-hard for a few hours depending on conditions, prior to adding a second or third coat.
  • Ensure coating is hard dry prior to use.
  • 2 coats medium corrosion. 3 for heavier corrosion.


  • RCP Can be sprayed by various means.
  • Buzzweld underbody gun. Extend the nozzle on the gun fully and set the pressure to a minimum of 90 psi. pressure can be elevated up to 150psi, the product warmed, or thinned to affect coverage, film thickness, and conditions of use. RCP will tend to spit in this gun, but as part of a kit to get the job done is passable. Product will self level to a degree once applied.
  • Buzzweld 1.8MM Suction Feed gun. Thin RCP using RCP Thinners up to 15%. Using a 400 Micron strainer load the gun with product, and set the pressure between 60- and 70 psi. Thin the MINIMUM so you can use less coats and save time.
  • Spray as per normal spraying instructions, building up the product. We would suggest you allow the product to cure for a few hours, and then apply a minimum of a second coat. Three would be ideal, but time or requirement may not permit this.
  • 3 coats medium corrosion. 4 for heavier corrosion. (2 can be used if not thinning too much, and corrosion isn't too heavy. you will need to use heavier coats, and adjust your cure and overcoating times accordingly).


RCP is unlikely to react with most products used correctly. Sensible guidelines to reduce the risk of product reactions are as follows.

  1. Ensure that any existing product to be top coated with RCP is FULLY cured prior to top coating. There is a big difference between hard and fully cured. For example 2 pack acrylics can be hard same day, but take up to two weeks to fully harden so that they can be machine polished.
  2. If a reaction has occurred, or is suspected, such as insufficient cure time available, then use a light first coat, with minimal thinner if spraying. If using an aerosol, then spray from a greater distance, and do not not flood, or build the product too fast. effectively "dust" the first coat. Subsequent coats can be applied with increasing build, and reduced risk of reaction
  3. If a coating reacts even after sufficient cure time, contact us for advise, or use a Barcoat Isolator as an intermediary coating.



Notable attributes

  • Stabilises corrosion using rust to protect the base metal.
  • Tough, touch dry coating, with good resistance to abrasion, and a high build
  • Superb wetting out properties reinforced with extreme resistance to porosity.
  • Ideal as a primer for WAR, CIO, HD Gloss, Gloss Extreme and 0


  • Always a minimum of two coats
  • Always allow the first coat a suitable cure period prior to second or third coat.
  • apply to dry, clean, non contaminated surface
  • Key the surface to a dull finish


  • Use fossil fuel heaters in or around coatings when applying or curing. They are not only a fire hazard, but they introduce massive amounts of moisture to the air.
  • Use Cellulose thinners of any kind as prep, or a thinning agent.
  • Use thinners to thin the product that are not RCP specific thinners. RCP is a specific hybrid coating, and using the incorrect thinners can cause premature failure, delamination, and porosity.
  • Apply to a wet substrate without specific advice from ourselves first.
  • Top coat existing coatings that are not fully cured
  • "Clean" the surface with thinners



  • 1/2 can per wheel arch
  • 6 cans for a small chassis 
  • 6 cans for a large chassis (if using a primer)
  • 8>10 cans for a large chassis no primer
  • 4 cans for a small chassis cavity
  • 6 cans for a large chassis cavity


  • 12M2/1000ML
  • 2500ML for a chassis and axles up to 110 size
  • 12M2/1000ML if top coating a primer with a smooth substrate
  • 8m2/1000ML if top coating a rough substrate with no primer
  • 300ML per average wheel arch (using two coats)

CURETIMES  (Typical)

Please be aware cure times can vary wildly. Air movement, film thickness, relative humidity, air flow and temperature all play a large part in the actual cure time of a product. Additionally temperatures below 10C can see the cure times extend exponentially if all conditions above contribute in a negative way.


  • 10C Touch Dry 40 minutes, Hard dry 4>8 hours, through dry 24>36 hours
  • 20C Touch Dry 20 minutes, Hard dry 1>2 hours, through dry 12>24 hours


  • 10C Touch Dry 90 minutes, Hard dry 6>8 hours, through dry 48>72 hours
  • 20C Touch Dry 60 minutes, Hard dry 2>4 hours, through dry 36>48 hours

Top Coating.

Rust Control Primer must be fully cured prior to top coating with another product. If you are top coating with a lower adhesion coating that isn't semi self etching like CIO Chassis In One then we recommend you lightly scotchbrite the surface to pride a mechanical key. This is useful with coatings like FXLiner, Raptor, Buzzweld1, and a whole range of dedicated top coats, making them more durable and less likely to chip.