DIY body rust repair product suggestions appreciated
#2564963
10/16/18 05:44 PM
10/16/18 05:44 PM
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Joined: Jan 2003
Posts: 15,439 Val-haul-ass... eventually
BradH
OP
Taking time off to work on my car
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OP
Taking time off to work on my car
Joined: Jan 2003
Posts: 15,439
Val-haul-ass... eventually
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Not for The MoPig, although the same thing could certainly apply to that car, too. This is my 2002 Subaru WRX DD that has a couple of spots in the rear quarter panels behind the wheel lips that have developed some WRust ( ![tonguue tonguue](/ubbthreads/images/graemlins/custom/tonguue.gif) ). I'm interested in doing the repairs myself, but would like some suggestions for what products would be effective in such repairs, especially on the passenger-side where the surface has cracked and the corrosion has spread much more already. I've done some online research and have a couple of ideas, but this will be my first "real" experience w/ body repair and want input from those who have been down this road before me. Thanks - Brad
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Re: DIY body rust repair product suggestions appreciated
[Re: FurryStump]
#2565002
10/16/18 06:54 PM
10/16/18 06:54 PM
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Joined: Jan 2003
Posts: 15,439 Val-haul-ass... eventually
BradH
OP
Taking time off to work on my car
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OP
Taking time off to work on my car
Joined: Jan 2003
Posts: 15,439
Val-haul-ass... eventually
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First-time body repair on my 16-YO DD... seriously doubt I'm buying a welder and taking a welding class for this (although it would be cool to know how!). What I have in mind at this time is to grind away the rot to clean metal, and use some type of metal-reinforced filler product after treating the exposed metal to try to keep the rust from returning. Does this fall under your "Basic Backyard Bondo" job? ![shruggy shruggy](/ubbthreads/images/graemlins/custom/shruggy.gif)
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Re: DIY body rust repair product suggestions appreciated
[Re: BradH]
#2565009
10/16/18 07:03 PM
10/16/18 07:03 PM
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Joined: Sep 2007
Posts: 14,889 up yours
Supercuda
About to go away
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About to go away
Joined: Sep 2007
Posts: 14,889
up yours
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filler, of any type, is a skim coat over good metal to make it look straight. It is not a replacement for gone metal, it will fall out. It is used as a replacement for craftsman level metalworking that doesn't need filler when done. I can't do that level of metal work, nor can I afford it.
There have been may lazy ass ways to try to get filler to stay, chicken wire, stuff it with newspaper, whatever. all fail and all fails.
They say there are no such thing as a stupid question. They say there is always the exception that proves the rule. Don't be the exception.
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Re: DIY body rust repair product suggestions appreciated
[Re: BradH]
#2565143
10/16/18 11:32 PM
10/16/18 11:32 PM
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Joined: Jul 2006
Posts: 488 Chilly Northern, Minn.
71 Charger R/T
mopar
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mopar
Joined: Jul 2006
Posts: 488
Chilly Northern, Minn.
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That is typical "Subie" rust. The quarters rust right at the shelf where the quarter meets the bumper cover. Rust coming from the backside like this will most likely necessitate replacement of some inner structure as well. (at least to do it right, it will) as far as the outer panel goes, you don't need to invest in a welder. Go to your local Harbor freight store and buy a flanging tool. ![](http://i228.photobucket.com/albums/ee187/71chargerRapidTransit/forum%20posts/Screen%20Shot%202018-10-16%20at%207.54.23%20PM_zpsgavipk12.png) Cut out the rusted area (rust is like cancer! The only way to stop it is to CUT IT AWAY!) and flange the edges around the hole, fashion a new piece of sheetmetal and "Glue" it back in with "Lord, fusor" product. The panel will be flush, completely sealed from moisture leeching through the repair into your plastic filler skim coat on the outer surface. The upside to this method is that you will not be burning away any of the factory E-coat on the back of the sheetmetal and leaving a new bare surface for rust to begin again. I live in the "rust belt" So I'm all too familiar with rust! This is the best way I have found to deal with rust. I was skeptical about "gluing" panels before doing it this way the first time. But do some research and you will find it to be just as strong as a weld and non- destructive to rust preventatives that are in place behind the panel. ![](http://i228.photobucket.com/albums/ee187/71chargerRapidTransit/Aris%20Stratus%20RT/DSC00054.jpg) This is on a 1992 Subaru SVX. You can see I had to rebuild the inner wheel house before gluing the outer patch panel on. I welded the patch into the inner wheelhouse but if you get fancy, you could glue that too. ![](http://i228.photobucket.com/albums/ee187/71chargerRapidTransit/Aris%20Stratus%20RT/DSC00055.jpg) Not a real great picture of the finished product, but it's all I've got. ![](http://i228.photobucket.com/albums/ee187/71chargerRapidTransit/Aris%20Stratus%20RT/DSC00057.jpg) If you just go the Bondo route, plan on doing it every year! Because it's only going to last about one season before it rears it's ugly head again. ![twocents twocents](/ubbthreads/images/graemlins/custom/twocents.gif)
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Re: DIY body rust repair product suggestions appreciated
[Re: BradH]
#2565146
10/16/18 11:36 PM
10/16/18 11:36 PM
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Joined: Jan 2003
Posts: 10,588 Freeport IL USA
poorboy
I Live Here
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I Live Here
Joined: Jan 2003
Posts: 10,588
Freeport IL USA
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These days, I might have some doubts that the $1500 repaint bill would include welding in new metal. My bet is the new patch is going to be glued in place.
You should cut out the rust, treat the metal with a rust converter (for the rust you missed cutting out), form a patch and glue the patch panel over top of the hole surrounded by the good metal, then add filler to the edges to make it smooth, and paint it.
Anything short of cutting out the old rusty metal and replacing it with new metal will guarantee the rust will return, possibly as soon as 6 months.
Once you do it yourself, and find out just how hard it really is, I'd bet the next time, that $1500 won't look so bad. Gene
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Re: DIY body rust repair product suggestions appreciated
[Re: poorboy]
#2565152
10/16/18 11:50 PM
10/16/18 11:50 PM
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Joined: Jul 2006
Posts: 488 Chilly Northern, Minn.
71 Charger R/T
mopar
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mopar
Joined: Jul 2006
Posts: 488
Chilly Northern, Minn.
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These days, I might have some doubts that the $1500 repaint bill would include welding in new metal. My bet is the new patch is going to be glued in place.
You should cut out the rust, treat the metal with a rust converter (for the rust you missed cutting out), form a patch and glue the patch panel over top of the hole surrounded by the good metal, then add filler to the edges to make it smooth, and paint it.
Anything short of cutting out the old rusty metal and replacing it with new metal will guarantee the rust will return, possibly as soon as 6 months.
Once you do it yourself, and find out just how hard it really is, I'd bet the next time, that $1500 won't look so bad. Gene I agree with everything except the last line. It's not really hard (and it's very satisfying) to do it yourself! By the time you're done, you'll probably have laid out about $700 doing it yourself. The chemicals are not cheap! Sandpaper, probably a few tools. (Flanger, spray gun, Long board, sanding block, Etc....) But you'll have some tools to show for it and some education to add to your portfolio.
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Re: DIY body rust repair product suggestions appreciated
[Re: 71 Charger R/T]
#2565171
10/17/18 12:54 AM
10/17/18 12:54 AM
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Joined: Jan 2003
Posts: 15,439 Val-haul-ass... eventually
BradH
OP
Taking time off to work on my car
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OP
Taking time off to work on my car
Joined: Jan 2003
Posts: 15,439
Val-haul-ass... eventually
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Ironically, I was thinking seriously about having the shop do the work when I had a self-inflicted incident while driving my wife's car that we bought in 2015. The repair estimates were within $50 of each other. Hmmmm... spend the $1500 repairing my wife's newer car, or spend it on my 150K-mile 2002. Only enough $ to fix one... and doesn't my wife's car look nice! So, it really does come down to a) I do something myself, or b) it doesn't get done at all. I appreciate the replies and will do further research to see what I'm willing to take on myself. EDIT: FYI, the estimate for repairing the WRX did NOT include repairing the rusted area by replacing the metal. They told me they would use some hi-zoot... epoxy? ... and, BTW, no warranty on rust repairs.
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Re: DIY body rust repair product suggestions appreciated
[Re: BradH]
#2565220
10/17/18 02:56 AM
10/17/18 02:56 AM
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Joined: Jan 2003
Posts: 4,437 Omaha Nebraska
Brian_wo
master
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master
Joined: Jan 2003
Posts: 4,437
Omaha Nebraska
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First answer was spot on. Buy a mig and go for it,you will be surprised how many uses you will find for it.
who is that guy?
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Re: DIY body rust repair product suggestions appreciated
[Re: Sixpak]
#2565302
10/17/18 12:13 PM
10/17/18 12:13 PM
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Joined: Jan 2003
Posts: 8,398 Highland, MI.
Sunroofcuda
master
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master
Joined: Jan 2003
Posts: 8,398
Highland, MI.
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Find a friend with a mig welder. Do it once, do it right. Grind it back til you get to solid metal. Overlay wide strips of tape over the hole, mark the contours and use as a template to cut a patch, then truck over to your friend with the mig. Grind back the welds, use some fiberglass bondo for the deep stuff, regular bondo for the light stuff. Sand til you get sick of doing it (get it flat and smooth), hit it with primer to see the high spots, sand some more. Prime and paint. Right here is the only way.^^^ Rust is like cancer, you have to eliminate it.
No Man With A Good Car Needs To Be Justified
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