Can I Fix a Zipper That Has Rusted Closed?

Determine whether a rusty zipper should be repaired or replaced by assessing the extent of the rust damage. Also consider the likelihood that the fabric will be damaged during the repair and the pros and cons of various rust removal processes and products. Weigh the time and costs associated with repairing the zipper, replacing it yourself or having it replaced by a professional. These considerations apply whether the zipper is in a garment or a piece of sporting equipment, such as a tent.

  1. Extent of Rust Damage

    • The extent of the rust damage determines whether a rusted zipper should be repaired or replaced. If extensive rust damage exists, often the cost of replacing the zipper is less prohibitive than the amount of time and energy you would expend and the possible damage to the surrounding fabric. However, you may want to consider rust removal methods if the rust damage to the zipper is minimal.

    Fabric Damage

    • Most rust removal products and processes will damage fabric. The acid in these products removes color and even melts some fabrics. If your fabric is destroyed in the process of repairing the zipper, time and money is wasted.

    Rust Removal Products and Processes

    • Rust may occur when metal gets wet. When oxygen atoms in water react with the iron atoms in metal, iron oxide (rust) results. Chemical rust removers rely on acid to convert iron oxide (rust) into iron phosphate. Residential users typically use of three types of rust removal products or processes: commercial products, "green" products and an electrolytic rust removal process.

      Commercial rust removal products encompass many liquid or gel-form commercial rust removal products. These products typically rely upon corrosive, toxic acids--such as hydrofluoric acid, phosphoric acid or hydrochloric acid--to remove rust. These products harm and can even melt some fabrics.

      "Green" rust removal products include mild, nontoxic forms of acids and items from your kitchen like lemon juice and vinegar to remove rust. The weak acids in these solutions take longer to remove and may not be effective. Green or natural products can harm fabrics.

      Electrolytic rust removal pulls the rust from the rusty item (connected to the negative pole of a low-voltage battery charger) and attracts the rust to a sacrificial piece of iron (connected to the positive pole of the low-voltage battery charger). Although this procedure is a safe, easy and cost-effective method that does not involve caustic chemicals, it is likely that the rusty water will damage the fabric attached to the zipper.

    Repair or Replacement

    • Compare the cost of repairing versus replacing the rusted zipper. Consider your financial expense, the value of your time, the likelihood that your zipper will work after you attempt to repair it and whether your fabric may be damaged. No one likes to spend money unnecessarily. However, if the zipper is "rusted closed," the zipper probably is unsalvageable.

      If the rusty zipper is in a garment, obtain a replacement zipper from a fabric store. Install the zipper, or ask your tailor to install the zipper for you. If the rusted zipper is in a piece of sporting equipment, like a tent, ask your shoe repair shop what they will charge to replace the zipper. You may be able to save money if you remove the old zipper (use a seam ripper to save time). All things considered, often the easiest option is to replace the rusted zipper.