I have some surface rust in different areas of my 2001 3500. I have tried to address some of it once and failed, the rust came back in a month or so. I used a wire wheel to remove any loose light rust, had pretty clean metal when finished, sprayed 2 coats of "rust converter" to stop any that wasn't removed. Then sprayed 2 coats of primer over that. The rust came back.

 I am not a body man but did this happen because I did not apply paint to seal the repair? I thought the primer would do that but I guess I was wrong.

 One day I would like to repaint the truck but for now I just want to do some touch up and fix any thing I can to keep her looking decent.

 Thanks for any input.

Primer does not seal out water or air.  If you want to leave it primer looking, you need to shoot clear over it.

 

I think that is what got you.  Try it again and use at least some rattle can enamel over the repair and see if that doesn't help. 

 

Take a look at more products.  I believe the rust converter is designed to take iron oxide and close its chains and make existing rust stop.  It will not prevent future rust from starting.  That is usually a different product (phosphoric acid IIRC)

 

Good luck!

 

Hag

Sandblasting, cut and weld + sealing oxygen off, paint or beer cans

Omg! Lol

 I will try redoing it but coating with paint and or clear coat when finished. 

 At some point I will be replacing some sheet metal also. Rockers, floor from bottom of the firewall to the front seat mount and the center section of the bed between the wheel wells. I think the goose neck hitch contributed to that rusting.

7 hours ago, Dieselfuture said:

Sandblasting, cut and weld + sealing oxygen off, paint or beer cans

At least  the cans the right color

OMG, those are Japanese beer cans.  I hope the truck doesn't morph into a Honda.

54 minutes ago, IBMobile said:

OMG, those are Japanese beer cans.  I hope the truck doesn't morph into a Honda.

No but I figured most things that last come from Japan so ....

There was a guy a while back that did a rocker panel repair and cab corner repair. He explained it all on the website here. I'll try to find it.

If you could that would be great. I've searched but I have trouble with the search on this site sometime. Don't know why.