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Orange rust dots on paint

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97K views 37 replies 21 participants last post by  macura2001  
#1 ·
Someone else asked me to write this article for them and I figured it was TI worthy so I'll post it here too. For anybody who doesn't want to read the whole thing, the second to the last paragraph is basically the summary of the whole thing. I spent some time explaining IFO and how to protect yourself from it before the info on how to remove it. Hopefully it is helpful. I think something of this length could be written about every aspect of detailing probably. There is a lot to know, but its not too hard to learn if you are interested. The knowledge of how to do this kind of stuff is going to be the edge you need when you are at a show with a hundred other tegs that are just as modified as yours is. It will all come down to the condition and cleanliness of the paint in the end.



What are those orange dots and how to I remove them and protect my car?

By: Anthony


The orange dots that most white car owners see and many other car colors simply hide is called Industrial Fallout (IFO) and is also known as Rail Dust. IFO occurs when particles from the atmosphere land on an unprotected car surface and then embed themselves in the paint. Typically this kind of thing is caused by brake dust if you do a lot of freeway driving. Hot brake dust coming off your brakes and the brakes of other drivers will land on your paint and melt right into the car much quicker than other forms. Rail dust is similar. Rail dust is named such because it is commonly found on cars that are transported by rail. Metal shavings from the rails fly up and melt into the car the same way brake dust does. It is protection from these kinds of IFO that cars are shipped with those protective plastic sheets on the hood and side mirrors and other parts of the car.

IFO also literally falls out of the sky. If you live in an industrial area then you are going to see more of this problem than if you lived in the country. Living near refinerys like I do puts me at greater risk of IFO than the average joe. Compound the fact that I have to do some freeway driving and I live a stone throw away from the freeway makes me even more at risk. Polution from these areas will collect in the atmosphere and just land where it falls. Usually that is going to be on cars parked and not doing anything.

The only way to 100% protect yourself from IFO is to never drive your car and keep a car cover on it. That not being an option for most of us, the other alternative is to protect the car in other ways. Keeping it washed is the first good way to prevent it. In the winter IFO is even worse than in the summer. All that brake dust and polution that doesn't land on your car right away is quickly deposited there in the form of slush and road spray. Ever notice how bad your car looks in the winter as compared to the summer? People go longer between washes because it just gets dirty again. That is not a good excuse. The same argument could me made for washing your dishes or cleaning anything else. What's the point in brushing your teeth? They are just going to get dirty again. You need to keep your car washed weekly if possible. In the winter when it is hard to get out there and do it then you need to at least take it to a drive through car wash or something. The paint on your car is the most expensive part of the vehicle. Even more expensive than the engine or anything else. It is also the most visible part of your car. If you ever plan on selling the car someday then you need to take care of the paint. That will be its best selling point when the time comes. Don't let your lack of washing it cost you hundreds or thousands of dollars on the resale value.

Another good way to protect your car from IFO is to use a high quality sealant on the surface. Waxes are great and everything, but they are merely for looks. Waxes won't protect you from IFO for very long. Imagine dipping your finger in a candle that has just been blown out. I remember playing with wax when I was a kid and I would do this all the time. The wax coats your finger and creates sort of a shell around it. If you bend your finger and then straighten it back out again, then you might notice that it isn't a skin tight shell anymore. The more you wiggle your finger the shell gets looser and looser. That is how wax works on your car. It creates a 'shell' around the paint that is temporary protection. In the heat your car will shrink a bit. When it gets cold it will expand. This shrinking and expanding will create space between the paint and the wax. Heat builds up in that space and will speed up the process of the breakdown of the wax. Even the best wax will only last around 6 weeks on your car before there are large areas of wax that have basically 'melted' away. Harsh weather like heavy rain or snow will wear down the wax as well. Using really strong soaps to wash the car will wear it down too. Wax is very oily, so using an oil cutting wash will pretty much remove all the wax. Dish soap is a very good example of this.

A car sealant is more like dipping your finger in super glue rather than wax. Super glue bonds to your skin right away. It will shrink and expand with your finger instead of pulling away. In fact, to remove the super glue you may need to use an abrasive pad or some other strong chemical. Sealants bond to your car in the same way. They bond on the molecular level. First the molecules bond to each other and then they bond to the paint. This creates a very strong barrier of protection that can last for many months. Some can last for 6 months or longer. Sealants are very good protection for your paint. There are many different kinds of sealants that provide a variety of appearances. Most are very glossy and shiney. The latest technology of sealants adds a depth and a 'wet look' that has always been the best quality of waxes and glazes. Now you can get the appearance of a wax and the durablility of a sealant.

The best part about a sealant is that it will protect your car from UV rays that will fade the car and oxidize it. It will also create a much slicker surface that IFO finds much harder to penetrate. If you have a good sealant on the car then IFO may land on the car, but it won't be able to work its way into the paint quite as easily. It will wash off instead of needing other treatments. If you live in a higher risk area for IFO damage then it is important for you to wash your car frequently and use a good sealant.

Now comes the part where we deal with removing the little brown dots. The reason they are brown is because most IFO is actually metal shavings and they rust when they get stuck in there. The brown stain is the rust that spreads from the little piece of metal. The rust stain can be cleaned off easily enough with a paint cleaner or a polish. That won't remove the metal shaving though. It will still be there. With enough of those metal shavings in your paint you could cause serious and irreversable damage to your paint that will eventually result in total clear coat failure. You have seen it before I'm sure. Cars that look like the hood needs to be repainted are cars that were badly taken care of to begin with. I've seen 15 year old cars looking better than 5 year old cars and it is all a result of proper car care on a regular basis.

The proper way to remove the IFO is to use a product called 'clay'. Not molding clay or earthy clay. This is a specifically designed for automobiles kind of clay. Clay Magic is the brand that I would suggest. You will find other brands on the shelf from companies like Mother's or Meguiar's, but Clay Magic is the brand that I like the best. I like it best for a number of reasons. Number one is the way that it sticks to your fingers while working with it. Some clay is just too hard and slips out of your hand too much. If you drop a clay bar on the floor then it is going to pick up little pieces of grit that are going ot do damage to your car. A dropped piece of clay is a lost cause and should be thrown away for safety. Clay Magic is sticky and I very very rarely have one slip out of my hand while working with it.

The way you use clay is very simple. You wash the car and rinse it like normal. Dry it as you usually would, but leave a little water here and there to help in lubricating the clay. Clay Magic usually comes in a kit that includes a bottle of spray lubricant. Using that with the extra water on the surface will make the job much easier.

Clay usually comes in a 100g sized bar. You can break that into three or four pieces very easily. Break off a chunk and begin with that. If you drop it then at least you didn't just throw away an entire bar of clay. one clay bar is good to clay probably half a dozen cars or more. You shouldn't need to worry about replacing this bar often. You won't really have to use it that often.

Using the spray lube provided with the kit, spray some lube on the surface of the car. I like to start with the front of the car on the hood or the fenders. Don't go too heavy with the lube. Just a spritz is really all you need. Then going in back and forth motions in the direction that the air blows over the car while driving, go about 10 or 12 inches at a time. Just rub it back and forth along the surface untill you have covered the whole car. Do not use clay in circular motions. Go in straight lines from front to back. Don't go up and down or in circles. There is no need to wipe down the area after you are done either. Usually I just pull the car back out of the garage and wash it again when I'm done. That is actually the easiest way to do it.

Claying your whole car should take about an hour. once you get good at it then it is possible to cut that down to 20 or 30 minutes. Its not a very hard job to do and the difference after claying is amazing. You will notice that the surface is noticiably smoother and has more shine. As you are claying you will feel that the surface grabs at the clay at first and then allows the clay to glide after a couple of passes. That is how you know the clay is working. It isn't rocket science at all. I am amazed everytime I explain the principle of clay to someone that they have never heard of it before. This is the easiest way to work by hand and actually repair damage and prevent future damage on your car.

After claying your car you can follow it up with whatever paint cleaner or polish you normally use. While clay will remove many of the black and brown dots that are caused by IFO, it may not remove them all. Using a good paint cleaner or polish will clean off the rest of the stains. The metal shavings are gone and all that remains is the stain. That should be easy to clean up as prepearation for a selant or a wax.

The only risk involved with clay is that you may pick up some grit in the clay and it could act as an abrasive on the car causing scratches. To avoid that, you should fold the clay often and inspect your work and the clay frequently. If you feel rough particles in the clay then you should try to either get them out of the clay or get a new piece. Folding only helps so much. If you have lots of gritty particles in the clay then its time for a new piece. Its not worth the scratches you could cause in the car if you choose to ignore the particles. Clay is cheap at a price of only about 10 bucks. Your paint is worth buying a new bar if you have run out instead of using a piece that is gritty and could cause damage.

To store your clay you should either choose a zip loc bag or some other kind of container that will protect it from dirt. 200 gram sized bars of clay usually come in their own box. I store my clay in an empty wax jar. Choose whatever works best for you. Protect the clay from dirt and it will be there to protect your car from IFO for a long time.

You should only really need to clay twice a year. I clay in the spring to clean up from the winter and then I do it again in the fall as I prepare the car for the winter. Unless you notice the orange dots coming back then you shouldn't need to clay more than that. The most common place for IFO to appear is the back bumper and trunk. That is where your own exhaust deposits polution and the wind blows your own brake dust behind you. Those areas may need to be clayed more often. Follow clay with the sealant or wax you normally use.

Well, that may seem like a lot of work, but it really isn't. This article is mostly informative rather than actual instructions. To summarize what is written, these are the steps you should follow:

-Wash the entire car with the car wash of your choice. You may leave a bit of water on the surface when drying to assist in the lubrication of the clay. To clay you just lubricate the surface with either a soap and water mixture in a spray bottle or with the lube included with the clay kit and glide the clay along the surface. Do not use circular motions. Rub the clay on the paint in straight lines from back to front in the direction the wind blows over the car while driving. The clay will grab at first and then glide with ease when the surface is clean. Do not drop the clay. Inspect it often for grit or other particles that could scratch. Clay the whole vehicle and then rewash the car. Apply a paint cleaner or polish to remove the remaining brown dots and then seal or wax.-

That is as much as I think I can say about how to handle those annoying dots that appear on your car. Don't just polish the car and be satisfied that the brown dots are gone. Protect the car properly with a sealant and remove the IFO with clay. That way the dots won't come back unless more IFO penetrates the sealant. Keep an eye on your car and care for it well and your paint should please you for many years.
 
#3 ·
The way I first learned about IFO was when I took my car to the dealership thinking that I was having some kind of paint failure on my back bumper. They wanted to charge me $200 to remove the damage. They said it was rail dust and only the dealership could remove it. Bah... I did some research and launched myself on a career in detailing and automotive restoration. There are several other ways to remove IFO, but clay is the easiest and most available to the average joe. It works just as well as what the dealership is going to do and it will only cost you about 3 dollars worth of product instead of $200.
 
#10 ·
The thing is that white is just the color that shows it the easiest. I'll bet if you look really closely at any car you'll see little brown and black dots all over the place.
 
#11 ·
Thanks for the excellent write-up Anthony.

"People go longer between washes because it just gets dirty again. That is not a good excuse. The same argument could me made for washing your dishes or cleaning anything else. What's the point in brushing your teeth? They are just going to get dirty again. You need to keep your car washed weekly if possible."

Well put!
 
#12 ·
So I'm learning about IFO just a little too late.
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This is the current state of my car...

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Before you get all over me for neglecting the teg... We've had constant terrential rainfall (extrememly rare in CO during the summer). In the meantime I've been moving, starting a new job, and planning a wedding (in a little less than a month). I have race brake pads on the car that I haven't had time to take off (long story). I thought the buildup was a combination of road grime and pollen (which we had a weird outbreak of not too long ago). The car has only been driven about 25 miles a week in the past month.

I discovered this was a problem last night when I ran the car through a carwash on the way home. Got out. Looked at the car and it was still dirty. I was like what the? So I went to a DIY wash and washed it by hand thinking it just needed some elbow grease. When that didn't get it off I realized I had a problem.

So my questions are...
-Are my wheels salvageable?
-Are there any techniques to remove IFO that is that thick?
-The area above my door moulding was really bad. I scrubbed the crevice with a tire brush. I hate to do that to the whole car. Is there another, more paint friendly, method to remove the top layer? (since I assume that much IFO would contaminate the clay very quickly)

Moral of my story: Don't use race brakes on the street!
 
#15 ·
That happened to my friend but his were worse (Ford Explorer Brake System EXPLOSIoN)...

The easiest way to go about this would be getting some Meguiar's Overspray Clay from our sponsor Premium Auto Care. Use it with a soapy water lube and do everything like Jngr has said above. This will 9 outta 10 times work.

If not, then you will need to have it wetsanded, compounded, and polished.

Since you already hit it with a wheel brush, it will DEFINATELY need to be polished professionally now since its gotta be all swirled.

Good Luck with it.
 
#16 ·
I haven't hit it with clay yet. I'm going to do that in a matter of hours. I have been planning on polishing it anyway. The paint on the front clip is only 3 months old. I have a couple clear coat runs that I needed to fix and then I was going to use Meguiars #2 (fine-cut cleaner) to buff the whole car. Would it make more sense to skip the clay and just use the cleaner?
 
#17 ·
Skiping the clay and going for the cleaner is like skipping the tweezers and going straight for the peroxide. You gotta pull the contamination off and out before you are going to get effective results with the cleaner. Always clay before cleaner. Clay is doing things that cleaner can't do. That is why it is there.
 
#18 ·
Servo, I just went back and checked out the pictures you posted. That is some really nasty stuff there. I definitely suggest that you start with clay to get some of that off. I don't know how effective it will be on your wheels, but definitely try it. Do the car first and the wheels next. Take the wheels off your car so you have full access to the whole thing. This is not going to be a quick and easy job. What you need is more than just detailing. You need restoration.

on the wheels I would first use some really good wheel cleaner. Don't use engine degreaser like a lot of people resort to. That won't help you and may damage your wheels. Use something like Eagle one A2Z. You can get it just about anywhere. Just look for the orange spray bottle. Spray that on dry wheels and let it soak for about a minute before hosing it off. You should also probably try getting a wheel brush and scrubbing on them for awhile before using anything abrasive like a polish. Hopefully most of that crud comes off with a little elbow grease, but we'll see. Post again if that doesn’t work.

on the paint I think you should definitely clay first. If you have anything that you think a tar remover might help with, then you can try that before you clay. After the clay I would suggest using a good non-abrasive paint cleaner like Klasse AIO. I have really seen some neat results using that. It will help clean off the rust dots as well as the dingy appearance of white paint. After the AIO I would use a cutting compound if there is still damage.

The kicker of this is that you aren't going to make much headway on the car if you do it by hand. It is going to wear you out and probably take 12 hours. You may want to consider investing in a PC so it will be more effective and actually work. Check out the article on OCDetails.com and check out the list. For about 300 bucks you can have everything you need to fully restore your car and maintain it for years. If you took that car to any detail shop I would guess they would charge you in the realm of $350-$500 bucks to restore the condition of that car. You will save a lot of money by doing it yourself.
 
#19 ·
Anthony, thank you for all of the info. I'm definitely going to need it to get those wheels clean. Unfortunately, my internet connection pooped out right after I posted the last time. So I went ahead and went to work with the clay. So after an hour and a half or so (with a friend helping) my response is... HOLY FREAKING AWESOME PAINT CARE PRODUCT BATMAN!!!!!

These are from a thorough first coat of clay. It got rid of 99.5% of what was covering my paint, including stuff that was there before this IFO disaster.
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You can see a little IFO around the signal in this pic. I'm going to pop those out this weekend when I have more time.
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Here's a great shot of what this stuff can do. Keep in mind that the grime in the pic could NOT be removed with soap, water, and mucho scrubbing. But the far side of the bumper is clean from just lightly rubbing with the clay. Just amazing!
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The wheels are going to be a bit more challenging. I'm going to take your advice and swap them out while I clean them. That will probably have to wait till this weekend, though. I was much much more worried about the paint than I am the wheels. They're only Rotas. I'll keep you guys updated as to what the outcome is. Thanks again for all of the help.
 
#24 ·
u think urs is bad.. i just got my rear bumper painted.. and it like melted into the paint.. and its permanent.. for some reason i never saw anything on my car before it was painted.. now that its painted.. its like theres no way of getting it off.. it looks like little rust dots that are the size of salt everywhere.. the body shop said they would reapaint it for free.. which is good.. but it still sucks.. since i paid 800 to have the fenders and rear bumper and spoiler all redone..
 
#26 ·
Sorry I never gave you guys an update on the wheels. They didn't make it.
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The only way to get the buildup off was with a tire brush or a scotchbride pad. Both of which took off the clearcoat and the paint. At present the wheels have some very dead Parada II's on them. I've got a couple more track days this summer, and then I'll have them repowdercoated over the winter. They'll probably get donated to a 4th gen hatch project I'm starting.