Had a similar issue a couple years back—thought I could just sand and repaint the rusty spots, too. Did yours make any weird noises before it started leaking? Mine started making these popping sounds, and I ignored it at first...big mistake. Ended up with a mini flood in the basement. Rust definitely has a way of hiding deeper problems. Are you leaning toward replacing it now, or still thinking repair might hold up?
Had a similar experience myself—rust is tricky stuff. Did yours start with just surface rust, or did you notice deeper corrosion right away? I remember thinking mine was just cosmetic at first, but when I finally got around to sanding it down, it was pretty clear the damage went deeper than I thought. And yeah, those popping noises you mentioned...mine made more of a rumbling sound, almost like gravel rolling around inside. Ignored it for a while, thinking it was just sediment buildup. Big mistake on my part too.
Honestly, from what I've seen over the years, once rust sets in, it's usually a losing battle. You might patch it up temporarily, but the underlying issue doesn't really go away. Have you checked how old your heater is? If it's nearing the 10-year mark or beyond, replacement might be the smarter move. I know it's tempting to save money and just repair, but water heaters aren't exactly forgiving when they fail.
On the other hand, if it's relatively new and the rust seems superficial, you might get away with a repair for a while. But keep an eye (and ear) out for any unusual noises or signs of leaks. Water damage cleanup isn't cheap, trust me—I learned that lesson the hard way.
Either way, you're smart to be cautious. Rusty water heaters have a sneaky way of turning minor annoyances into major headaches pretty quickly. Good luck with whatever you decide.
I see your point, but I'm not convinced rust automatically means replacement. Had a heater at one of my rentals that showed surface rust pretty early on—maybe 4 or 5 years in. My handyman sanded it down, applied some rust-inhibiting primer, and painted it. That thing lasted another 6 years without issues.
Granted, if you're hearing weird noises like gravel rolling around inside, that's probably sediment buildup rather than rust itself. Flushing the tank once or twice a year can help a lot with that. I've had units pushing 12-13 years with regular maintenance and no significant problems.
Not saying replacement isn't sometimes necessary...but rust alone doesn't always mean the end is near. I'd take a closer look before shelling out for a new unit.
"Granted, if you're hearing weird noises like gravel rolling around inside, that's probably sediment buildup rather than rust itself."
Good point about sediment buildup—I had a similar issue a couple years back. Flushing definitely helped quiet things down. Still, I'm skeptical about patching up rust long-term. Surface rust is one thing, but if it's deeper corrosion, wouldn't that compromise the tank's integrity eventually? Curious if anyone's had success with more serious rust repairs lasting beyond just a few extra years...
Had a customer last year who insisted on patching a rusty tank. We cleaned it up, applied rust inhibitor, and it looked decent at first... but honestly, within about 18 months the rust came back worse. Deeper corrosion usually means the metal's already weakened, so patches are more like temporary band-aids than real fixes. Personally, I'd start budgeting for a replacement sooner rather than later.
