RODNEY and GARRY ROSE, the inventors and builders of the WIRE FEED SPRAY WELDER, started out as Idaho farm boys. On their parents' farm, they learned to weld as a practical skill in order to keep the farm equipment running.

Garry became a tool and die machinist and was so good that he was chosen by Howard Hughes to do the glass connectors on the U-2 aircraft. Afterward, he went to Hill Air Force Base to become a certified aircraft technician. His natural inventiveness and bent for practical problem solving helped move him forward in every aspect of his career.

His younger brother, Rodney, after serving in the Air Force, dispatched for a trucking firm, then moved into corrosion control for such large food processing plants as Green Giant and Carnation. It was Rodney's job to solve rust problems and prevent buildup of rust in the processing equipment to eliminate the inclusion of rust in the product.

The brothers always collaborated well on different projects, and were together in Idaho in 1978, working on repairing a badly rusted pickup cab corner. Using a poorly designed flame spray metallizing machine, they re-created the corner of the cab using spray foam, a hacksaw, and a hammer. As Rodney said, "Of course the pickup caught fire in the corner a couple of times in the process. Then we practiced on things like grain elevators and bullet holes in old trucks and cars."

They tried every other type of welding machine, and they decided to create a welding machine that was practical, effective, safe to use, and accomplished a permanent rust repair on metal using only metal ... no plastic fillers. They had been disappointed by the existing devices out there. With their work and life experience, they knew they could do better.

Through trial and error, they developed their WIRE FEED SPRAY WELDER that creates a cooler application by mixing air with the special metal compound. "We practiced filling rust holes," Rodney said. "At first, we had to remove fenders, put a piece of metal in back, then spray the area. We could fill places as big as your head." Then they learned how to do the rust repair without removing the part, using air ... no more metal backing. It was more difficult and more expensive, but it lasted longer. The longer it lasted, the cheaper the repair became. They found that using the same metal as galvanizing gave them complete corrosion control. The metal compound they created could be shaped like the lead that ws used in "the old days," a big advantage for body repair.

Don't make the mistake of thinking that paint stops rust and corrosion as well as our galvanized metal compound. The ASTM (American Society Testing Manufacturing) SSTC 20 USA test for paint is very different from a full metal coating like we apply, ASTM A780, at Rustbusters. For paint, full failure occurs when the last flake of paint falls off the metal. With a metal repair, full failure is described as when the surface shows 5 percent rust. The product was tested for 20 years. You can read this in the American Welding Society International Standard Book, No. 0-87171-111-7.

Our machine simply works better than anything else out there. All the machine owners listed on this website (see locations) have been trained by us here at Rustbusters. Check us out! It is practical, high quality, American made, and it works, it works, IT WORKS!


RUSTBUSTERS' Wire Feed Spray Welder is NOT the cheapest way to repair your rust holes ... unless you consider how long the repair lasts. We figure you can expect that repair to last 100 years!

If you actually prefer plastic filler, do not call about our machine. It uses nothing but galvanized pure metal.

When traditional shops weld in replacement panels, the process actually wrps that part being fixed due to the high heat of welding and the expansion and subsequent shrinkage involved. Also, at the weld points, the steel of the part being repaired loses its corrosion control oil (part of the manufacturing process) which, in turn, invites rust to occur. This has been tested by the American Society of Testing Manufacturing (ASTMA780). Using the Wire Feed Spray Welder, the temperature of the application only gets to 120o Fahenheit which does no damage to the steel of the part. THere is no warpage as a result. There is no loss of corrosion control oil, therefore no corrosion results from the repair.

Some welders use plastic filler to hide their weld marks. We don't have to since we are not welding. Our unique system sprays pure molten galvanized metal mixed with air. We apply 2 mils of metal at a time, and can layer that thickness up to 1 foot thick.


Sandblasting is the best surface preparation before using the Wire Feed Spray Welder to repair rust holes. It cleans the area better than sandpaper or steel wool. Once you have purchased our machine, part of our training process includes our specific sandblasting techniques.

Painting the repaired, galvanized surface makes the paint last longer with NO RUST. Galvanized metal and paint are synergistic to each other. The paint lasts longer because the galvanized metal prevents moisture from attacking the steel under the galvanizing which would loosen the paint. Galvanizing lasts longer because the paint prevents moisture from attacking the surface of the galvanizing, which would loosen the paint. Galvanizing lasts longer because the paint prevents moisture from attacking the surface of the galvanizing. Galvanized surfaces are very receptive to these liquids coatings: true epoxy and polyurrethane.

A repair done with plastic filler may look good ... at the beginning. However, plastic fillers have a longevity problem. The longer a plastic filler repair is in place the more likely it is to develop one or all of the following: shrinking, cracking, lifting, peeling, corrosion, and rust.

RUSTBUSTERS' Wire Feed Spray Welder has no such problems ... we use no plastic filler, just pure galvanized metal. There is no shrinkage, cracking, lifting, peeling, corrosion, or rust. You can work the filled hole or repair with a file. What an advantage to the body man. Furthermore, the galvanized repaired part, once it is painted, will last almost indefinitely, since any rust or corrosion will stop at the galvanized repair surface. Rust may continue to affect the back side of a repaired surface, but simply stops when it touches the galvnized repair.

The Wire Feed Spray Welder can be used for portable galvanizing on-site. There are no limitations to the size or shape of the surface to be repaired. And it is not subjected to the extreme heat of hot dip galvanizing.


  • LEAD as a body filler is dangerous to use, because it is a heavy metal. The fumes from using molten lead as a filler are highly toxic, and the effect is cumulative, even to the point of death.
  • HOT DIP GALVANIZING: When you weld hot dip galvaning, the gas that is given off is arsenic, and is dangerous and highly toxic.

    When you do the repair using the Wire Feed Spray Welder, no arsenic gas is involved, nor lead fumes. However, the process is drying to the eye membranes. That is why we teach the new owners of the machine to always wear a mask with eye protection while operating the machine. If you breath the fumes during the process within a closed space, you will get "fume fever" the same as during the galvanizing process. We encourage our machine owners to perform the process outdoors, or with excellent ventilation.

    How We Started

    In 1978, my brother and I discovered a method of repairing rust holes in cars and trucks without cutting out the rusted area and welding in new material. Now, we sandblast the affected area and spray new metal into the hole.

    Our process is also effective for food processing companies who like the idea of not having to repeatedly paint their plants. We have also galvanized the bars at the Newport Oregon County Jail, to prevent rust and increase paint longevity.

    We now manufacture the specialty equipment required for this metal application process. Since the Rustbusters name is on the line, we insure quality by providing training and updates to equipment and processes.

    Click here to find out more...

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