For a project I need to make a metal sign. It needs to look like it's rusted but not truly rust. Any ideas?

Question

This is for a Boy Scout Eagle Project. The sign will be outdoors. It is in a desert area. The sign will need to be engraved. It can't actually be rusted but must look like it is. This fake rust needs to last for a long time.

Answer 1

Hey Nick B,

The type of metal and conditions are what you might focus on. Rust left alone on metal in a desert will actually protect the metal under the rust - as long as you do not scrape the rust off. So, why not use the real deal? Real Rust.

Prepare your sign, spray it with water so that it forms a protective rust cover. There are automobiles that were abandoned, and barrels left in the desert that have been there for up to one hundred years! Is that long enough? I would use a thick carbon steel (1/8"), and the height and width you need.

You might consider welding the sign letters on. Prepare all the letters by cutting them from a slightly different material.

Lot of possibilities here. The key to a good project is for you to learn as much as possible, and for it to provide a benefit for as long as possible. Good luck.

RustSkipper.

Answer 2

to make a fake rust from paint (and this works well with either oil or acrylics), i use burnt umber (paint called that colour) with just a tad of raw sienna (a pinch to barely lighten it)...
you can get artist's oil or acrylics in colours named burnt umber and raw sienna, or you can go the 50cent route and use those apple barrel / annita's type craft acrylics with the same colours...(and they work just fine for nearly any project)

Answer 3

most all signs are now made of aluminum . visit your local paint store or a home depot .
OH, i thought that was rust . Usually is .