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In some climates there'll be flash rust in a couple of hours. I kept having it pop up after using store bought metal prep(as per instructions) but didn't have any with POR15s "Metalready".
The single chemical cans are useless. Use the 2-stages polymer types and a primer made for raw metal so it has the self etching to get rid of incidental rust and that will actually stick to the metal. The zinc coating should be protecting the raw metal as a sacrificial layer, so rust coming back is odd.
BTW, I hope POR15 works because I've done the interior, trunk and entire underside(especially wheel wells) with it and so far am impressed with the tough shell. It dosn't fix rust itself, and doesn't stick well to loose or greasy paint or smooth surfaces.
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