When a homeowner’s basement bulkhead appeared to be past its prime, she sent up a flare to the team at Ask This Old House. Not knowing whether to replace the bulkhead or paint it, she relied on paint expert Mauro Henrique to help her make a decision and even choose the right color to match the backyard.
How to Paint a Rusty Bulkhead
- Start by taping off the area around the bulkhead. Use painter’s tape along the edge where the bulkhead meets the siding, and then tape plastic sheeting to painter’s tape and spread it over the siding. Tape in place as needed.
- Put your respirator and safety glasses on for this step. Scuff the surface of the bulkhead with the sanding block. Light sanding over the painted areas is fine, but be sure to remove any loose or flaking paint. Make sure the surface is smooth, and take note of any areas where bare metal is exposed.
- Vacuum the surface of the bulkhead to remove any dust and dirt. Be sure to use a brush attachment to ensure any contaminants are removed.
- Shake the spray primer well and apply a thin coat of primer over any of the areas of exposed metal. Allow the primer to dry.
- Pour the DTM (direct to metal) paint into the paint tray. Use the roller to apply the paint to the field of the doors and the paintbrush to cut in along the edges or undersides of the door or bulkhead where the roller won’t fit.
- Allow the first coat of paint to dry (drying times will vary by temperature and sun exposure) before applying a second coat of paint.
- Keep the door as clean as possible and sand and repair any problem areas that might arise in the future.
Pro Tip: Mauro, painting expert on Ask This Old House, explains why sanding is so critical: “You don’t have to sand down to bare metal, just enough to remove any peeling paint or rust. If you didn’t do this, any loose paint will eventually flake off, taking the new paint with it.”
Resources
Prep the bulkhead doors for painting by vacuuming cobwebs and removing excess dirt with a dry cloth. Once the doors are free of debris, use a 220-grit sanding block to lightly sand the rusted areas and vacuum any excess dust. Apply a coat of metal primer spray to the rusted areas for extra protection against corrosion. Use a combination of mini paint rollers and brushes to apply the first coat of DTM (Direct to metal) paint. Start by cutting the edges of the bulkhead doors with a brush and move to using the mini rollers for a streak-free finish. Let the first coat dry before applying the second coat.
Catch It Early: According to This Old House general contractor Tom Silva, bulkhead doors can last a long time if they’re properly maintained. The key is to watch for early warning signs: “The first signs you wanna look for is little chips in the paint, a little bubbling… First thing you wanna do is scrape it, sand it, prime it and paint it. A little chip or a bubble will grow” into a much bigger problem that could require full replacement.
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Pro Tip: When painting metal, choosing the right primer matters. Mauro, painting expert on Ask This Old House, cautions that water-based primer “is not good for metal in general,” and recommends using an oil-based primer instead, which blocks odor and stains and will hold up better against the elements.
