Can You Use Rustoleum Paint Over Powder Coat? (Explained) (2023)

Powder coating is one of the most durable finishes in the auto industry. Though durable, powder coating won’t last forever. After some time, it will experience wear and tear.

And it can expose the metal part beneath to oxidation and corrosion. As a car owner interested in protecting their investment from the effects of rust, you may consider painting Rustoleum over a powder coat.

Rustoleum is a metal paint and primer that can be used to protect surfaces. It can prevent and stop the spread of rust.

Like powder coat, Rustoleum is also a popular type of coating in the auto industry. With that in mind, let’s circle back to our question of the day.

Can you use Rustoleum over a powder-coated surface?

Rustoleum can be painted successfully over powder coat only if you adhere to certain instructions. As it is, a powder-coated surface can’t hold Rustoleum paint.

If you spray Rustoleum directly to powder coat, it will not hold. You must engage in thorough preparation. And by preparation, we mean scuffing up the powder coat.

What you have to understand is that paints only adhere to rough surfaces. The smooth nature of a powder-coated surface is what proves to be a challenge when painting Rustoleum over a powder coat. The second thing you have to keep in mind is a thorough cleaning of the surface.

Before spraying Rustoleum paint over a powder coat, you must ensure the surface is free of contaminants such as wax and grease. That can be achieved by using a strong solvent or paint thinner.

These will interfere with adhesion and can ruin your project. If you can adequately prepare the powder-coated surface, it should be very easy to spray Rustoleum paint over the powder coat.

Why Would You Paint Rustoleum Over Powder Coat?

Now that we have figured out that it’s possible to paint Rustoleum over powder coat, we must ask ourselves why anyone would want to engage in such an act.

People have different reasons for spraying Rustoleum over powder coat. The first is to enhance the protection against rust. As mentioned earlier, even though powder coat is durable, it won’t last forever.

If your car is exposed to a lot of moisture and road salt, which accelerates corrosion, you can benefit from the extra protection offered by Rustoleum.

The other reason people paint Rustoleum over powder coats is to improve the finish. As the saying goes, beauty is always in the eyes of the beholder.

Some people don’t like the powder coat finish. It’s why they would prefer to touch it up with some Rustoleum paint. In the process, they can also change the color of the finish. It’s more of a personal preference.

Irrespective of your reasons, this project needs to be handled carefully, lest you will not be pleased with the results.

Why Rustoleum and Not Other Paints?

If your goal is to change just the aesthetics, you may wonder why I should only use Rustoleum and not any other paint.

You first have to know that you don’t need to use Rustoleum paint over a powder coat. You can use anything. But it would be in your best interest to use Rustoleum. We will explain why.

You apply powder coat to a car so that you can protect it from the effects of the environment such as oxidation, scratching, and many other things.

If you had powder coated your car, then it means you are mindful of preserving and protecting it from the environment.

If you are that keen on protection, then it would make the most sense to go for a paint that is as durable as what’s beneath.

If you were to use ordinary car paint, it would be better to let the powder coat stay as it is. That’s because ordinary paint will wear out much sooner than Rustoleum.

The latter happens to be a very durable coating that will work alongside the powder coat to protect your car from the dangerous effects of oxidation.

How to Paint Rustoleum Over Powder Coat?

It’s a fairly easy process that doesn’t require many tools or expertise.

Step 1 – Gather the Essential Requirements

There are a couple of things that you will need to pull off this project. Obviously, you will need some Rustoleum paint. We prefer the ones packed in spray cans since they are easier to use.

You will also need very fine sandpaper, preferably 200grit. It’s also advisable to purchase a strong cleaner or a paint thinner.

Step 2 – Preparation (Scuff the Powder Coat)

The best way to approach the scuffing of a powder-coated surface is to wet sand it with a 200grit sandpaper. It will be much easier and more effective at roughing up the surface.

Make sure that you sand thoroughly until there are no shiny spots. If you see shiny spots, then chances are, you missed a spot. Once the entire powder-coated surface is dull, move on to the next step.

Step 3 – Strip Off Any Contaminants

Even if the surface were just powder-coated days ago, there would be contaminants. Don’t risk painting Rustoleum over contaminants.

To strip off these contaminants, you will need to apply your cleaner of choice to the powder coat. Acetone works great, and so does paint thinner. Wipe it off with a rag, and then let it dry.

Step 4 – Spray Rustoleum Paint on the Scuffed Powder Coat

Your powder-coated surface would be ready for paint application. Therefore, grab your spray can and get to work.

Remember, Rustoleum is both primer and paint, so there will be no need for spraying primer on the surface. Shoot several coats of Rustoleum paint to get a better finish. Let it dry before taking your vehicle out for a spin.

Is Rustoleum Tougher than Powder Coat?

We have already covered why anyone would want to spray Rustoleum over a powder coat. But for those wondering, Rustoleum isn’t as tough as powder coat. Out of all coatings, a powder coat is the most durable.

It can withstand the harshest conditions for years. A surface that has been powder coated will receive longer protection than one that has just been painted with Rustoleum.

You should go for both Rustoleum and powder coat if you want ultimate protection.

What are Some of the Challenges of Painting Rustoleum Over Powder Coat?

Even though it’s possible, there are several challenges that you should anticipate. Familiarizing yourself with these challenges will help you avoid making mistakes that would interfere with the final finish of your project.

The first challenge is in regards to adhesion. As mentioned earlier, the powder coating surface is flat and very smooth. If you have done some painting in the past, you are well aware that paint doesn’t adhere to such a surface.

It’s why in our process of how to paint Rustoleum over powder coat, we talked a great deal about scuffing the surface with sandpaper. When you do that, you create a rough surface on the powder coat for Rustoleum to hold on to.

The other challenge is matching the performance of these two coatings. There is no comparison between Rustoleum and powder coat. The latter is tougher and more durable.

If you were accustomed to the strength of powder coat, that of Rustoleum might slightly disappoint you since it’s not as durable. Anyway, compared to regular paints, Rustoleum is much better. And it’s an ideal alternative.

Fortunately, you can overcome all these challenges. Regarding the adhesion, provided you scuff up the surface, the paint should hold with much ease.

Regarding matching the performance of powder coat, Rustoleum is one of the most durable paint jobs on the market. It may not be as strong as a powder coat, but it will get the job done.

We didn’t list one thing as a challenge, but you need to get it right, and that is the mode of application.

Besides the scuffing, you also need to clean the powder-coated surface. Grease and other contaminants can prevent the adherence of Rustoleum. Make sure that you follow our guide keenly.

Can I Paint Rustoleum on Worn Out Powder Coat?

When painting Rustoleum on a powder coat, the latter surface must be intact. If it’s worn out, your Rustoleum paint job will not last.

When the powder coat has worn out on some parts, the best solution is to remove the powder coat and apply a new layer of powder coat.

Alternatively, you can remove the powder coat and directly spray the Rustoleum. The areas where the powder coat has worn out will have an unsmooth surface, affecting your finish.

Is It Okay to Paint Rustoleum Over Rusted Surface?

Rustoleum can prevent and stop the spread of rust on metal. If the powder coat had worn out and some parts had started rusting, you can still paint Rustoleum over it.

But first, you will have to sandblast the rusted area, apply filler then spray Rustoleum. Remember not to rush such a project because, quite often, a lack of adequate preparation can reduce the lifespan of the Rustoleum paint.