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dlhoovler

Rust! Advice?

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Here are some pictures of the rust I investigated while getting my '02 out of storage yesterday.

This is the driver's rocker panel just ahead of the rear wheel.

Rust-1.jpg

A bit farther ahead, by a rocker-panel drain.

Rust-2.jpg

Both of the previous spots with some context. I know there are two thicknesses of steel here, which probably explains why this rusted but farther forward is clean.

Rust-3.jpg

Passenger's rear shock tower, with two small spots. These are solid when poked with a screwdriver, almost seeming like they rusted from inside the trunk, although I know it's more likely that they've been rusting from the other side, where the boxed area above the spring is welded to the wheel well.

Rust-4.jpg

Closeup of the forward rust spot on the shock tower.

Rust-6.jpg

Closeup of the rear rust spot on the shock tower.

Rust-5.jpg

The passenger's rear rocker panel.

Rust-7.jpg

Ziebart did a good job on this car when it was new--the only rusty spots now are places of double-thickness steel where it would have been almost impossible to get to. There are two other small spots that are purely cosmetic on the rear wheel arches, but I'm not too worried about them at this time.

I know the rockers will need attention; any ROUGH guesstimates on cost to have this done (I can't weld)? And is it likely that a good body shop could fabricate basic patch panels for this area, or should I plan on ordering factory patch panels? The car isn't a show car, just a good-looking driver.

Second, in the trunk, how can I determine what needs to be done? It still seems solid, so I'm tempted to hit it with primer and paint and leave it, but I know that's asking for trouble down the road. I guess I need to scrape the undercoating off of the other side of the wheel well, or is this seam actually inside the box section?

Thanks!

-Dave

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And yes, there's a way to get between the two layers of outer rocker panel that's aft of the door opening (denoted by the vertical seam in the rocker panel sheet metal).

mike

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I planned on bringing them, Mike. Gotta get the rust expert's advice! :-) Just thought I'd post as well to see what others thought.

-Dave

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experience with '02 rust! Some more than others. Your car is amazingly rust free for having spent most of its life in PA and NY...

See ya Thursday.

mike

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Guest Anonymous

Dave,

It looks like the sills nearest wheel well have had some rot for awhile. I would recommend stripping and grinding the entire length of both rockers and fully examining, rocker rust will creep up there, in the front near the jack point and at the seam by the handled edge of the door.

I recently completed a similar repair to this by cutting out sections of the rocker, resurfacing the underneath and welding in selected patches. If yours is similar to this, this could be done without cutting into the quarters (i.e. no repaint).

I have this repair fully documented and could send you photos, just let me know your email. I'd also be interested in quoting on this repair if you'd like. My shop is located in Cleveland, Oh. Feel free to call or email.

Thanks,

Mike O'Toole

(216)374-4788

[email protected]

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