Best Way To Repair Rust

[feb 47]

What is the best way to repair rust that has just started to appear between two pieces of metal that are folded and spot welded together?

 

This is in the wheel arch in the joint where the outer metal sheet meets the inner one and my wheel has been rubbing.

 

Thanks!

[welshpug 1,657]

Drill a few spot welds and separate the panels, treat and spot weld back together.

 

Sounds easy doesnt it

[Dizzee stuff 33 1 Cars]

The rear 1/4 panels are bonded to the inner arch, this sometimes cracks & lets in water and the rust starts. It is possible to scrape out the adhesive clean between the panels with emery cloth treat the rust and re-bond with panel bond.

[boldy205 75]

For treating the rust, i have used Jenolite with good results.

[Batfink 201]

To treat I'd be taking it down to bare metal. Chemically treat then re seal. Then give a good coating of waxol or other branded underbody protection

Edited June 16, 2013 by Batfink

[feb 47]

This is the offending area

 

 

It doesn't look so simple and my main concern is cleaning/removing all the rust in between the metals.

 

What do you reckon?

 

They have "only" just started to separate (although I guess this has been there for the last 2+ years) so by cleaning/removing the rust, chemically treating, priming and painting it will be good for another 3 years minimum but I don't know.

 

I am worried that spot welding the drills, separating the metals and welding them again together might do more harm than good if not done properly.

Edited June 18, 2013 by feb

[joshsnoad 2]

POR15, google it, a bit expensive but trust me it's worth it. You won't have to touch it again!

[feb 47]

POR15, google it, a bit expensive but trust me it's worth it. You won't have to touch it again!

 

Have you used it yourself and for how long tested?

There are mixed reviews here although it could be down to a bad preparation.

Edited June 18, 2013 by feb

[GLPoomobile 958]

It's worth removing the interior trim so you can see what you're up against from the inside.

[joshsnoad 2]

Have you used it yourself and for how long tested?

There are mixed reviews here although it could be down to a bad preparation.

 

Yer i have, although only two years ago. I think the problem most people have is the prep, i wire wheeled all my bits down first so it was it was pretty much clean rust free metal. then used the cleaner, then the prep ready, then finally two coats. It really sets hard, like ceramic tiles, and i havent had any flaking, peel or even signs of rust coming back through. Am I sounding a bit like a POR15 salesmen! lol. anyway i think its really good and i wouldnt use anything else now, but i guess some people have different experiences with it. hope this helps

[feb 47]

OK., good.

The question is the panels have started to separate (the metal still looks fine though) and unless they are bonded together water will seep into the gap and cause a problem lower down IMHO.

How would you seal teh gap or bond the panels together?

I have not decided whether to tackle this myself or take it to a professional to fix. I spoke to someone but they really need to see the car and can't judge from a photo.

[welshpug 1,657]

Is this on your subaru so something still worth a few k right? If so i'd personally let a pro sort it if you are not confident.

[feb 47]

Yes, Subaru. I am stripping the shocks to find the cause of this (hopefully either a shot bump stop or damper is the cause)

If I find out the info I am after I am willing to give it a try myself as after speaking to a professional I didn't get the answer I was expecting (using waxoil to seal is a thing of the past IMHO)

Edited June 25, 2013 by feb

[welshpug 1,657]

it wont be the damper at fault, but the wheel fitment!

[feb 47]

it wont be the damper at fault, but the wheel fitment!

 

This happened while on the OEM wheels with OEM tyre size, I don't see how it can be the wheel fitment?

Edited June 25, 2013 by feb