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Old 05-03-2015, 04:03 PM   #1
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Galvanized metal dock repair


Hi everyone! Hoping someone can help me with some repairs we need to make to our dock.

Previous owner had a very large (8x24) dock constructed with heavy duty metal floats that are galvanized. Over the past 10-15 years the minerals in the water have cause the metal to rust. Most spots are just surface rust but some spots where the end caps are welded look a little deeper.

Had a local metal worker and dock builder take a look at it. He recommended using a grinder with wire cup to remove rust then special epoxy he has for filling over the bare metal.

Having never used a wire cup on grinder before did some research and this venture sounds dangerous! People talking about metal wires flying off and embedding in skin- ouch!

Some sites recommend a manual wire brush and tremclad special primer for galvanized. Likely gonna be way more elbow grease but maybe safer???

If we did use tremclad would prefer brush on since don't want it to go everywhere but it also needs to be okay to sit in freshwater lake all summer long.

Has anyone tackled something like this before? Or can someone recommend the best course of action?

Thanks in advance!
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Old 05-03-2015, 04:10 PM   #2
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If you wear leather gloves and eye protection,you will be pleased with the angle grinder and wire cup or wheel----it is the tool for the job---and a cheap tool--
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Old 05-03-2015, 04:38 PM   #3
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Thanks Mike. Would you recommend twisted metal or just crimped?
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Old 05-03-2015, 05:04 PM   #4
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I think either one will work--the twisted ones last longer-----buy one of each and see which one is best for you---

Let the tool do the work---the tips of the wire are what removes the paint and rust--so avoid pressing down to hard and bending the wires to much---

Those tools are handy to have around the house---great for cleaning the BBQ grill--handy for cutting metal--can be used to cut tile----I think you will be pleased--

I have some cheap Harbor Freight ones and a few good Makita ones--they all work well---I like to have one for each use so I don't have to keep track of the different cutting wheels and brushes.
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Old 05-03-2015, 05:20 PM   #5
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Quote:
Originally Posted by oh'mike View Post
If you wear leather gloves and eye protection,you will be pleased with the angle grinder and wire cup or wheel----it is the tool for the job---and a cheap tool--
I agree,
I have spent most of my adult life working in around metal mfg. The wire wheel will do an excellent job removing scale and rust. Eye protection is a must and should include a full face shield.
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Old 05-03-2015, 06:00 PM   #6
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Quote:
tremclad
Ayuh,.... Isn't that the Canadian version of Rustoleum paint,..??

For what yer doin', Coal tar epoxy is the thing to use,....

Use a 4" roller, 'n a brush,.....

'n I agree, I use grinder brushes nearly daily, no fear, just wear clothing,...
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Old 05-03-2015, 06:06 PM   #7
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Indespensable tool with alot of uses... I've got a bunch also....
(Changing wheels is a PIA and there should be a universal size/fit for wrenches)

(I sure like the paddle switches for some reason).
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Old 05-03-2015, 06:58 PM   #8
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Quote:
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'n I agree, I use grinder brushes nearly daily, no fear, just wear clothing,...
ayuh, clothing is always good when using a wire wheel/cup. I tried it once without and let me tell you, well, you probably don't really want to hear so I won't.
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Old 05-03-2015, 07:38 PM   #9
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Thanks everyone. I don't think we will be attempting this sans clothing - flying wire aside not sure the neighbours would appreciate it. Haha
Yea tremclad is the Canadian name for rustoleum. Guy I talked to mentioned an epoxy - is that enough to do it or do we have to paint afterward?
Sounds like a crap job but if we re gonna keep the dock afloat it must be done!
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Old 05-04-2015, 05:09 AM   #10
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Ayuh,.... Coal tar epoxy..... Not just epoxy,....

No paint over it,....
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Old 05-21-2015, 12:39 AM   #11
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most wire cups cant go the rpm's of a std angle grinder. maybe they meant a variable speed angle grinder?
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