Preparing rusty metal for welding involves several steps to ensure that the weld is strong and durable. Clean the metal: Use a wire brush or grinder to remove as much rust as possible from the metal. This will ensure that the weld is made on clean metal and not rust, which can weaken the weld. Remove any loose rust: Use a wire brush or scraper to remove loose rust flaking or peeling off the metal. This will prevent the rust from getting into the weld and weakening it. Clean the metal with a degreaser: Use a degreaser to remove any oil or grease from the metal. This will help to ensure that the metal is clean and free of any contaminants that may weaken the weld. Dry the metal: Make sure the metal is completely dry before welding. Any moisture on the metal can cause hydrogen cracking in the weld, which can weaken the weld. Apply a rust inhibitor: Apply a rust inhibitor to the metal to help prevent rust from forming on the metal after welding. This will help ensure that the weld will last a long time. Preheat the metal: Preheating the metal before welding can help to reduce the risk of hydrogen cracking in the weld. This can be done by using a torch or an electric heating element.