Repairing an Expedition Roof Rack

[Dobby]

After a large bird hit the front of my roof rack a while back I've recently noticed that the plastic coating on the front panel of the roof rack has started to peel off. I have since removed the majority of the coating that was peeling off and the steel work behind it has started to rust. does anyone have any ideas as to the best way to repair it. I've thought about removing the remaining 'unsound' plastic coating' and cleaning it up and painting the damaged area. Is there a way that I can stop the rust 'creeping' onto the rest of the bar work or can I get it recoated with the plastic type coating?
Many thanks
Vince

[Don 130]

Get a small bottle of Penetrol. Apply it two or three times to the open ends of the plastic coating, about a week apart, so the previous application has a chance to dry somewhat before you apply more. you're trying to plug up any space there and seal it off. The Penetrol is very good rust treatment and can be mixed with the paint when you come to paint it. Read the label.
Don.

[steveG]

Get a small bottle of Penetrol. Apply it two or three times to the open ends of the plastic coating, about a week apart, so the previous application has a chance to dry somewhat before you apply more. you're trying to plug up any space there and seal it off. The Penetrol is very good rust treatment and can be mixed with the paint when you come to paint it. Read the label.
Don.

x2

Penetrol is definitely good stuff (not to be confused with Penetrene which is a completely different type of product).
Readily available from Bunnings and goes a long way so you'll only need the smallest bottle as Don suggests.
24hrs should be plenty of time between coats though IMO.

It definitely goes well mixed into 3M Chassis Black paint (got mine from Supercheap). Holding up well after about 6 years and made brushing it much easier than straight from the can.

From memory I've had a couple of spray cans that weren't happy going over the top of the Penetrol, so suggest you do a quick test with the paint on a separate piece if you go that way. Applying by brush with some Penetrol in the paint would be the easiest way and you'll be surprised how good the finish ends up.

Steve