Rust on Step Bar

[John G]

The gray tubular step bars on my '01 now have significant but not devastating rust, mainly along the seams.



There's a rust stripe about 1/4" to 1/2" wide running intermittently along about 1/4 of the total length of the seams, plus a few other dime-size rust spots that are not on seams.



Nothing is rusted all the way through, and the step bars are still strong and sound. There's no rust anywhere else on any painted surface, just the step bars.



The OEM replacement step bars are $388 for the pair, painted, from the parts counter at the local Ford dealer.



I'm not sure whether it's best to replace with OEM parts, with aftermarket (I haven't searched for any yet), or go to a body shop.



Has anybody dealt with this?

 

[Jake Levin]

The step bars are notorious for rusting. I sanded mine down and painted them with army stencil black paint. last about a month before the rust came back.

 

[Chris Joyce]

noheat, it's funny that you post this cause I just said the same thing about mine yesterday. This Saturday I plan on removing them from my ST, taking off the step pad and grinding the rust down, then re-painting them. My step bars have rust along the seams on both sides.

 

[Nelson Atwell]

It was a common problem in the early years. Many had to repaint their stepbars. I believe there is even a project here on it. I can't find it, but I did find the project to remove the plastic step pads to begin prep for painting. I suspect you will find even more rust under the step pads.

 

[Sal Adinolfi]

I sanded mine down and sprayed them with a Bediner Spray paint. (Black)



No rust now. and it has been about a Year.



you could always take them to a Spray-on Bedliner place and have them do it.

That should last a long time.

 

[Dallas Starr]

ebay!



heres one quick search and a stainless steep (no rusting) solution.



cheaper too (175.00 afetr shipping)



and this is just a quick search, Im sure you can find something you want.

 

[John G]

The project mentioned by NelsonOKC is helpful.



It included this photo of the brackets:

where the red stuff is clay, but the project author mentioned that in the Midwest you might get rust there.



Anybody know how common rust is on the brackets? I'm wondering whether I should also replace the brackets if I replace the step bars.

 

[Brian T]

Sal A. do you, or anyone have any pics of the bars done with the bed liner spray. I was thinking about getting mine done but was wondering what it looks like. Thanks.

 

[Nelson Atwell]

Those old style brackets are much sturdier than the newer ones. If you replace them make sure you get the older style.

 

[Chad Merry]

If your ST has an offroad look (lifted, Etc) go with some rock sliders instead. I am going to install a set on my ST before my trip to Moab.



These are what I am going to install. I will be getting rid of my stock bars after

I get these put on.





[Broken External Image]:

 

[Chuck Birnie]

Sandblasted and powder coated mine,no rust yet. They still look really sweet!!

 

[Richard Kolb]

I had mine sanded and linexed, they're not rusting but I've had a few chunks taken out from people hitting them with their doors.

 

[DougRuth Davenport]

I removed mine, disassembled all the plastic parts on them, sanded them down, treated them with rust inhibitor, primed them and gave them one coat of brush on bed liner from JC WHITNEY and let them dry, reassembled them completely and then finished up with the brush on bed liner over the whole thing, plastic step treads, end caps, and all to seal out all moisture. Reinstalled them and they have been on for a year and show no signs of wear, Minnesota road salt didn't seem to affect them at all. Total cost about 60 bucks and my time.