Costs, types & prevention

Average cost of car rust repair in Australia

Rust repair costs in Australia generally range between $506 and $942. Minor surface work can be a few hundred dollars, while major repairs involving structural elements may exceed several thousand.

Factors include:

• Rust type (surface, scale, or penetrating)

• Vehicle make/model

• Repair location (e.g., underbody vs. door panel)

• Labour rates and workshop location

Types of rust and what they mean for your repair bill

Surface rust

• Appearance: Light orange or brown patches on paint or exposed metal.

• Cause: Minor chips, scratches, or prolonged moisture exposure.

• Fix: Sanding the affected area, applying a rust treatment, and repainting.

• Cost: Typically $50 to $500, depending on area size and location.
  
  

Scale rust

• Appearance: Bubbling, flaky, or crusty areas.

• Cause: Progression from untreated surface rust, affecting deeper metal layers.

• Fix: Grinding, rust converter application, sometimes minor panel replacement.

• Cost: Ranges from $200 to $2,000, based on severity and accessibility.
  
  

Penetrating rust

• Appearance: Jagged holes or weakened metal sections.

• Cause: Long-term exposure resulting in structural corrosion.

• Fix: Cutting out the rusted section, welding new metal, repainting.

• Cost: Can range from $500 to over $5,000, depending on the extent of the damage.
  
  

Factors influencing rust repair costs

• Extent and depth of rust damage

• Location on vehicle

• Vehicle make and model

• Local labour rates

• Additional repairs like respraying

Recognising and addressing rust early

• Visual clues: Paint bubbling, brown streaks, flaking metal

• Common areas: Wheel arches, undercarriage, door frames, roof channels

• Conditions: Coastal or humid regions accelerate rust
  
  

Tip: Coastal and humid Australian regions face faster rust formation. Regular inspections help avoid costly repairs.

DIY vs. professional rust repair

DIY repairs

• Suitable for: Minor surface rust

• Approach: Sanding, applying rust converters, priming, and repainting

• Cost: Under $100
  
  

Professional repairs

• Suitable for: Scale or penetrating rust

• Approach: May involve welding, cutting, full panel replacement

• Cost: $500–$5,000+
  
  

Preventing rust from returning

• Wash and wax regularly

• Repair chips and scratches immediately

• Clean the undercarriage after exposure to salt

• Store in a garage or under cover

• Consider professional rustproofing

Finding trusted rust repair specialists

Rust repairs are best performed by qualified professionals.

Tips When Booking:

• Confirm if repairs include repainting

• Ask about rustproofing

• Ensure quotes include labour and parts

• Read verified reviews

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