Removing paint from metal surfaces can be a difficult task, even with the right tools - just ask the new guy at any auto body shop. Whether you’re getting ready for a DIY job or professionally prepping a metal surface, it’s a good idea to strip away paint the right way from the start. Below are some of the different techniques you can use to get rid of layers of paint from metal surfaces, from small pieces of hardware to larger jobs like stripping paint from a classic car.

Before You Begin: Know Your Metal, Paint, and Safety Needs

Identify Your Metal: The 10-Second Magnet Test

Start by finding out what kind of metal you’re working with:

1. Grab a common magnet and touch it to a clean spot on the metal.
2. Magnet sticks → Ferrous metal (steel, cast iron). Stronger, tougher, can handle more aggressive abrasives.
3. Magnet doesn’t stick → Non-ferrous metal (aluminum, copper, brass). Softer, lighter, needs a gentler touch.

Knowing this prevents damage and guides your abrasive choice.

Identify Your Paint: The Rubbing Alcohol Test

Next, you’ll need to figure out the type of paint:

1. Dampen a clean rag with rubbing alcohol, acetone, or nail polish remover.
2. Rub a hidden area for 15–30 seconds.
3. Color transfers to rag → Latex/acrylic (water-based). Easier to soften or dissolve.
4. No color transfer → Oil-based, alkyd, or enamel. Tougher; usually needs stronger chemicals or abrasives.

This is a quick test that saves time and money by matching the right removal method to your paint.

Assess Your Project Scope and Safety Needs

• Project Scale and Location: Is this a small piece of hardware or a large metal gate? The size and location (indoors vs. outdoors) will dictate your method.
  • For indoor work, use low-odor/low-VOC chemical strippers or abrasive methods. Avoid methods that create excessive fumes.
• Potential for Lead Paint: If the metal was painted before 1978, you must assume it has lead paint and test it.
  • NEVER dry sand or use a heat gun on lead paint; this creates highly toxic dust and fumes.
  • The safest removal methods for lead paint are wet scraping or using chemical strippers.

Safety First

Before trying any of the paint removal techniques we’ve outlined below, we always recommend using the appropriate safety gear. Basic safety gear will consist of a mask, eye goggles, and gloves. However, you may also want to add some type of protective apron and/or tarp.

Essential PPE and Workspace Checklist

• Eye Protection: Chemical-resistant safety goggles.
• Hand Protection: Chemical-resistant gloves (e.g., nitrile or butyl rubber) for solvents, and durable work gloves for abrasive methods.
• Respiratory Protection: A properly fitted N95 respirator or a half-mask respirator with appropriate cartridges to protect against dust, paint particles, and chemical fumes.
• Workspace Preparation: A well-ventilated area (preferably outdoors), with drop cloths or tarps to contain debris and spills.

If you are opting to use chemicals to remove paint, you want to make sure you are protected from the likely possibility of fumes caused by this method. Working in a well ventilated area and using an N95 mask is recommended for all paint and rust removal.

Removing Paint Without Abrasives

While we recommend using abrasive tools for most paint removal jobs, there are a few options available that you can choose instead. Abrasives will get larger jobs done faster and more uniform, but the next few techniques are best when you have smaller objects or don't have access to power tools like an angle grinder or linear grinder.

Removing Paint from Metal with Baking Soda or Vinegar

If you do not want to use a lot of chemicals then you can first try common household ingredients to loosen paint. This is one of those DIY hacks you can do at home with materials you likely have laying around. It takes some time to complete, and is only useful for smaller metal objects, but it does work well.

For the home DIY paint removal method you will need:

• A large pot or pan (that will never be used for food again)
• Baking soda or white vinegar
• Water
• Tongs
• Stiff-bristled brush or old toothbrush

Step-by-Step Instructions:

1. Create the Solution: Place the metal items in the pot. Fill with enough water to completely submerge them. For every quart of water, add 1/4 cup of baking soda OR 1/4 cup of white vinegar.
2. Heat the Pot: Place the pot on a stove or hot plate and bring the water mixture to a gentle boil or simmer…NOT a rolling boil.
3. Simmer: Let the solution simmer for 30 to 45 minutes. You should see the paint begin to soften, bubble, and peel away from the metal.
4. Remove and Scrub: Carefully turn off the heat. Using tongs, remove one item at a time from the hot water. Be extremely careful as the item will be very hot. Immediately scrub the item with a stiff wire brush or old toothbrush to remove the loosened paint. Most should come off easily.
5. Rinse and Dry: Once all the paint is removed, rinse the hardware thoroughly with clean water and dry it immediately and completely to prevent flash rusting.

Chemical and Solvent-Based Removal (For Intricate and Multi-Layered Surfaces)

There are many paint removing chemicals available to choose from, so the exact directions will vary somewhat depending on which product you ultimately choose. Below is a general overview of how chemical paint removal should be done, but you should always check the manufacturer’s instructions before attempting this method.

What You'll Need:

• Appropriate paint stripper (Citrus/Soy-based or Solvent-based)
• Chemical-resistant gloves and goggles
• Respirator
• Natural bristle or disposable chip brush
• Plastic or metal scraper/putty knife
• Plastic wrap (for gels)
• Container for waste
• Mineral spirits or water for cleanup

Method 1: Eco-Friendly/Biodegradable Gels (Citrus & Soy-Based)

These are the safest chemical options, ideal for indoor or poorly ventilated areas.

1. Preparation: Put on all PPE. Make sure all of the metal surface is clean and dry.
2. Application: Using a chip brush, apply a thick, generous layer of the gel stripper to the painted surface.
3. Dwell Time: Cover the coated area with plastic wrap to prevent the gel from drying out and allowing it to remain active for an extended period…often up to 24 hours. This technique is especially effective for stripping multiple layers of paint in a single application. Refer to the manufacturer's instructions for recommended dwell times.
4. Removal: After the recommended time, test a small area with a scraper. The paint should be soft, bubbled, and easily lift away from the metal. Scrape the softened paint and stripper goo into a disposable container. For intricate areas, use a stiff brush or old toothbrush to remove residue.
5. Cleanup: Follow the manufacturer's instructions for cleanup. Most eco-friendly strippers clean up with water or mineral spirits. Ensure all residue is removed before proceeding to the next step.

Method 2: Powerful Solvent-Based Strippers

These are fast-acting but require strict adherence to safety precautions. They are best for tough, industrial, or baked-on coatings.

1. Preparation: Work outdoors or in a very well-ventilated space. Put on all PPE, paying special attention to gloves and respirator. Protect the surrounding area with drop cloths.
2. Application: Pour a small amount of stripper into a metal or glass container. Using a chip brush, apply a liberal coat to the surface.
3. Dwell Time: These strippers work quickly. Within 5 to 30 minutes, the paint will begin to bubble, blister, and lift from the surface.
4. Removal: Once the paint has lifted, use a metal scraper to remove the softened layers. Work in one direction and collect the waste for proper disposal.
5. Neutralization and Cleanup: Don’t skip this step!. After scraping, wipe the surface down thoroughly with a rag soaked in mineral spirits or the neutralizer recommended by the manufacturer. This removes any remaining chemical residue that could interfere with new paint adhesion.

Method 3: Pure Solvents (For Specific Paint Types)

Solvents are best for small jobs or specific paint types.

• Acetone: Highly effective for removing spray paint and some lacquers. Apply with a rag and scrub. It evaporates very quickly.
• Denatured Alcohol: The specific choice for removing latex and acrylic paints. Apply with a rag and use elbow grease.
• Mineral Spirits: Less aggressive than acetone, useful for dissolving oil-based paint splatters and for general cleanup after using other strippers.

Chemical Paint Removal Safety

Chemical use can be a bit more dangerous depending upon the one you are using. Some paint removal chemicals are advertised as safe, usually made with a citrus base, and considered safe. Other chemicals can be highly toxic and/or contain dangerous acid, requiring you to wear PPE and to use them outdoors or in a well ventilated area.

Make sure you familiarize yourself with the solution you are choosing and if it is appropriate for the paint type you are removing. Before starting any chemical paint removal, you should review the chemical compatibility with your safety gear and metal, and make sure you have all of the recommended safety gear such as tarps, brushes, different masks, a fan, etc.

Thermal Removal: Removing Paint from Metal with Heat

Removing paint with heat is common and can be done on both wood and metal. This can be achieved with a blow torch (on metal) or a heating gun (both wood and metal). However, these can generate toxic fumes, so it is extremely important you wear a mask.

Metal will retain heat and, depending on the type of metal, can soften/weaken it. So, it is important when working with heat that you proceed with caution and start with a small test area if you’ve never worked with heat to remove paint off metal.

What You'll Need:

• Electric heat gun
• Heat-resistant gloves and safety goggles
• Respirator (essential for older paint that may contain lead)
• Metal scrapers (various shapes and sizes)
• Wire brush

Step-by-Step Instructions:

1. Preparation: Put on all PPE. Clear the work area of any flammable materials. If working on a vertical surface, be mindful of hot paint drips.
2. Heating: Set the heat gun to its lowest effective temperature setting. Hold the nozzle 3 to 6 inches from the surface and keep it constantly moving in a slow, sweeping motion to distribute heat evenly. Holding it in one spot can scorch the paint and warp the metal.
3. Observe and Scrape: Watch the paint closely. In a few seconds, it will start to bubble, wrinkle, and soften. As soon as this happens, remove the heat and immediately begin scraping the softened paint off with a putty knife or scraper. Timing is key here…if you let the paint cool, it will re-harden.
4. Teamwork Helps: For larger projects, this method is most efficient with two people: one person operates the heat gun while the second person follows immediately behind with the scraper.
5. Detail Work: For crevices and detailed areas, use a wire brush or a scraper with a contoured edge to remove the softened paint.
6. Final Cleanup: After scraping, allow the metal to cool completely. Lightly sand the surface to remove any remaining paint residue and to prepare it for priming.

While the heat will get quite a bit of the paint off, you may get stuck with some residue or stubborn paint that won’t come off with just the heat. Usually you can sand off any remaining paint fairly easily. If you are concerned about removing too much material, you try starting with a finer grit of 200+. The finer you go the longer it can take to remove the paint. But, if it is a piece with intricate detail you may want to go as fine as 320 and work slowly.

Removing Paint from Metal with Abrasives

There are quite a number of ways you can sand paint off metal. It is usually the fastest way to remove paint, rust, and other surface contaminants or imperfections that leaves less of a mess behind. You can use different tools like a portable belt sander, angle grinder, straight grinder, orbital sander, or even a drill. Each of these power tools has a specific paint stripping wheel or belt available.

The Best Abrasives for Stripping Paint from Metal

• Easy Strip & Clean Discs - gentle and surface-safe, making them ideal for delicate metal surfaces or projects where you want to avoid damaging the underlying material.
• Crimped Wire Wheels and Brushes - for reaching into curves and contours to remove paint from irregular shapes and intricate designs without harsh abrasion.
• Flap Discs - high-speed material removal on flat or slightly contoured metal.
• Knotted Wire Abrasives and Resin Fiber Discs - best for heavy-duty paint stripping jobs, tackling heavy-duty paint, rust, and scale on robust metals where significant material removal is required.
• Sanding Belts and Sanding Discs - versatile for use with sanders and grinders, these cover a wide range of paint removal tasks, from large surface cleanup to final smoothing.
• Abrasive Drums - for quickly stripping paint from large, flat metal surfaces with a linear grinder.
• Sandpaper - For precise control and detailed work, especially on small areas or for final touch-ups where power tools are too aggressive

What You'll Need:

1. Appropriate power tool (angle grinder, drill, orbital sander)
2. Abrasives product of choice (listed above, techniques below)
3. Safety goggles, gloves, and respirator
4. Hearing protection (for angle grinders)

Easy Strip & Clean Discs (Gentle, Surface-Safe)

In most cases, this type of abrasive is one we often recommend as the best paint remover for metal. There are many options available, but these easy strip and clean discs are the products made specifically for removing paint and rust from metals and hard woods.

• Application: These non-woven nylon discs are engineered for removing rust, coatings, and many other surface contaminants without removing the base material. They are the superior choice for auto body panels, aluminum, and any application where preserving the original surface integrity is paramount. They run cooler and are less likely to load up with paint compared to traditional sandpaper.
• Technique: Attach the disc directly to an angle grinder. Use light pressure and let the disc do the work. Keep the grinder moving constantly across the surface to avoid heat buildup and ensure a uniform finish. Their open-web structure makes them safer than wire brushes and prevents gouging.

⚙ SHOP EASY STRIP & CLEAN DISCS ⚙

Large Areas (Angle Grinders):

• 5” paint stripping discs
• 4 1/2” easy strip discs
• 4” easy strip discs

Small Areas/Detail (Die Grinders):

• 3” paint stripping pads
• 2” roloc strip discs

Linear Grinder (Fastest Removal):

• Easy Strip and Clean Abrasive Drums

Crimped Wire Wheels and Brushes (Light to Medium Duty)

Crimped Wire Wheels and Brushes are excellent general-purpose tools for paint removal.

• Application: The flexible, crimped wires are less aggressive than knotted wires, allowing them to conform to irregular shapes, curves, and corners. They are ideal for cleaning paint from wrought iron railings, machinery parts, and textured surfaces.
• Technique: Attach the appropriate wheel, end brush, or cup brush to a drill or angle grinder. Use moderate pressure. For softer, non-ferrous metals like brass, use a brass wire brush to prevent scratching and galvanic corrosion. For steel, a carbon steel brush is effective.

⚙ SHOP CRIMPED WIRE WHEELS AND BRUSHES ⚙

Large Surfaces (Angle Grinders):

• 4” Crimped Wire Wheel Brush (Carbon Steel)
• 4”Hub Crimped Wire Cup Brush (Carbon Steel)

Curves/Recesses (Power Drills):

• 3” Crimped Wire Wheel Brush (Carbon Steel)
• 2” Crimped Wire Cup Brush (Brass Coated)

Tight Interior Corners (Detail Work):

• 1” Crimped End Brush (Steel)
• 3/4” Crimped End Brush (Carbon Steel)

Stationary Cleaning (Bench Grinder):

• 6" Crimped Wire Wheel for Pedestal Grinder, Carbon Steel

Flap Discs (Fast Removal for Durable Metals)

When speed is the primary objective on durable surfaces, flap discs are unrivaled.

• Application: Flap discs are designed for angle grinders and can do a great job removing paint faster than most other tools. However, most angle grinder flap discs are designed to work for heavy stock removal. You should try not to force too much pressure when using a flap disc to remove paint. They are best suited for large, flat, or gently curved ferrous metal surfaces like steel plates or frames.
• Technique: This method requires a controlled, light touch. Forcing too much pressure will quickly remove not just the paint, but the metal underneath. A best practice is to use a staged grit approach: start with a coarser grit (e.g., 60 or 80 grit) to remove the bulk of the paint. Once about half the paint is gone, switch to a finer grit (e.g., 180-220 grit) to remove the remainder without aggressively removing the base material.

⚙ SHOP FLAP DISCS ⚙

General Purpose (Angle Grinders):

• 4-1/2” Zirconia Flap Discs (T29, Conical Shape)
• 4-1/2” Zirconia Flap Discs (T27, Flat Shape)

Specialty/Detail Work:

• 4-1/2” Curved Edge Fillet Weld Flap Disc
• 2” Curved Edge Fillet Weld Flap Disc

Aluminum/Non-Ferrous:

• 4-1/2” Calcium Coated Flap Disc for Aluminum (T29 or T27)

Mini/Die Grinder:

• 3” Mini Flap Disc Zirconia Quick Change (Roloc)
• 2” Mini Flap Disc Zirconia Quick Change (Roloc)

Resin Fiber Discs and Knotted Wires (Heavy Paint & Rust Removal)

These are your most aggressive options, and should be saved for when paint is stubbornly bonded or there’s also heavy rust or scale to deal with.

Knot Wire Wheels

• Application: The twisted-knot design delivers a powerful, chisel-like cleaning action, ideal for removing thick, layered paint, weld spatter, and baked-on coatings from heavy steel or cast iron.
• Technique: Use a firm two-handed grip on your grinder, as knot wheels can grab edges and kick back. Move evenly across the surface with steady pressure—enough to let the wires bite, but not gouge. These leave a rough surface profile, so follow up with a finer abrasive before priming or painting.

Resin Fiber Discs

• Application: Resin fiber discs are a close rival in aggressiveness, but offer a smoother, more controlled cut. These abrasive discs—made with aluminum oxide, zirconia, or ceramic grains—excel at stripping paint and corrosion from broad, flat metal surfaces like automotive panels, doors, and frames.
• Technique: Mount the disc on a backing pad and attach to an angle grinder. Start with a coarser grit (24–36) for heavy paint or rust, then move to medium (60–80) to refine the surface. Maintain a shallow grinding angle (10–15 degrees) and consistent motion to avoid gouging. They’re perfect for blending after wire wheel use or when you need to prepare the metal for primer.

⚙ SHOP KNOTTED WIRE & RESIN FIBER DISCS ⚙

Heavy Duty Stripping (Angle Grinders):

• 4" Knotted Wire Cup Brush (Carbon Steel)
• 4” Knotted Wire Wheel (Carbon Steel)

Cleaning Recesses (Drill / Die Grinder):

• 1-1/8" Knotted End Brush (Tempered Steel)

Resin Fiber Discs (Aggressive Flat Surface Prep):

• Zirconia Resin Fiber Discs

• Ceramic Resin Fiber Discs

• Aluminum Oxide Fiber Discs

Sanding Belts and Sanding Discs (Versatile for Power Sanders)

One of the most common methods for removing paint is using either sanding belts for metal or an angle grinder sanding disc. While you can use the resin fiber discs or flap discs as we mentioned earlier, we have found sanding belts, hook and loop sanding discs, or the PSA sanding discs work better. The reason for this is that flap discs and resin fiber discs are very aggressive and can remove far too much metal once you’ve gotten through your coatings.

Sanding Belts

• Application: Best for large, flat, or cylindrical metal surfaces, sanding belts are available in a wide range of grits and abrasive materials. Use coarse grits (40–60) for paint removal, switching to finer grits (120–220) for finishing.
• Technique: Keep the belt moving smoothly with light, even pressure. Don’t press too hard; let the abrasive do the work.

Sanding Discs

• Application: Hook-and-loop or PSA sanding discs used with orbital sanders are great for controlled paint stripping and finishing work, especially on panels or smaller surfaces.
• Technique: Start with coarser grits (60–80) for removal, and refine the surface with higher grits (180–320). Avoid lingering in one area to prevent swirl marks or heat discoloration.

Abrasive Drums (Large-Area Removal)

Abrasive Drums are excellent attachments for surface conditioning tools and linear grinders (like the Eastwood SCT), designed to cover a large surface area very quickly.

• Application: Drums are ideal for quickly stripping paint, rust, heavy scale, and body filler from large, flat surfaces or tubing on heavier metal parts. The Easy Strip and Clean Abrasive Drum is a favorite for auto body and metal workers because it quickly cleans and strips while leaving the underlying surface intact.
• Technique: An Easy Strip and Clean Abrasive Drum can remove paint from a large area incredibly fast with a linear grinder or surface contouring tool. Other abrasive drums, like the interleaf flap wheel drum, are also available for 2-in-1 paint removal and surface finishing.

Hand Sanding Metal (Small Details & Touch-Ups)

This is usually the cheapest option, but one we don’t recommend in case you are looking for a serious workout. This method is best if you are just trying to get rid of paint from a small metal object or doing some touchup work after any of the techniques above.

• Technique: Start by cleaning off any loose paint and dirt from the surface. Just like sanding and removing paint from wood, you should start with coarser sandpaper sheets to remove the most paint and move up to finer grits as you get closer to the metal surface. Scuff hand pads (Scotch Brite pads) make a great final step to hand sanding when you want to prep the surface for a fresh coat of paint.

FAQ

We’re Here to Help

Hopefully this article was able to help you best decide how to remove paint from metal, but if you still have any questions, Empire Abrasives knowledgeable agents here to help. You can contact us at 1-800-816-3824 or chat with an agent on empireabrasives.com.