What should I do about all the rust on my car?

[CROYCE992]

I love my car plenty but it seems like every time I am washing it or removing one panel or another I find rust EVERYWHERE! The worst is the ones attacking my quarter panels which I can't simply just unbolt and replace. Last fall I tried sanding off till I got to bare metal and applied a rust inhibitor from Ace then a primer from Rustoleum and then a layer of paint from Rustoleum = End result, this spring noticed that rust is forming underneath and everywhere else for that matter.

Any suggestions?

[Chris Crash]

Pictures would help to be able to see how far it's gotten.

[CROYCE992]

Originally Posted by Chris Crash

Pictures would help to be able to see how far it's gotten.

Definitely, I will snap some pictures ASAP. Probably won't be till 7PM CST at the earliest though.

[CROYCE992]

Rear Driver's Side quarter panel right where it meets with the rear bumper:


Rear Driver's Side wheel well - right above the wheel:



Bottom of my Driver's Side door (this is not my original door - was replaced with one from my parts guy after an accident):


Rear Passenger's Side Quarter Panel and Wheel Well:



Rear Passenger's Side Door bottom - original door - (most likely will have to replace this door as this is the largest and seemingly worst spot on the car - Don't want to because factory alignment will be lost on the door):


Front Passenger's Side door bottom (my original door):

[Chris Crash]

A lot of that can be ground down and repainted.

The rear quarter panel and door may need to be patched.

[bigbird]

rust is like a weed. it has to be completely removed or it will come back. deep sanding and cleaning will help that but it may be started or worse on the opposite side of the pannel or door.

[PhatRoyale]

Looks like there is already bubbling forming, which means that the rust has gone through the metal.

It's too late to save.

You're only option to prevent it from spreading further is to cut out the old panel and weld in a new one.

[Nervous]

Not just sand it, but also treat it by POR15.

[CROYCE992]

Originally Posted by Nervous

Not just sand it, but also treat it by POR15.

One of my friends recommended that I use POR15 too. I was thinking about sanding down to bare metal where possible and treating it with this stuff but I am totally unfamiliar with it.

[Nervous]

You can find info on their site. For example (video how to use it): http://www.por15.com/whatispor15.asp
It is easy to start with their starter kit: http://www.por15.com/SUPER-STARTER-K...ductinfo/SSKB/

[PhatRoyale]

If you're lucky you'll hit bare metal and be able to repair it with POR15.

The other scenario is that the panel will shatter like glass due it become too brittle with rust.

In any event, you should go into this project with plans to weld in new body panels if all else fails.

[CROYCE992]

I finally got around to checking out the POR15 website and noticed their Super Starter Kit for about $20. It offers everything I need to get started treating the rust and seems to have enough to cover all the effected areas. I think I am most likely going to place an order for this in the next few days and try sanding to the prime metal again (this time making sure I do a good job of containing it so that it doesn't spread) and using the the three stage kit.

What do you guys think?

[933VZFE]

Originally Posted by CROYCE992

I finally got around to checking out the POR15 website and noticed their Super Starter Kit for about $20. It offers everything I need to get started treating the rust and seems to have enough to cover all the effected areas. I think I am most likely going to place an order for this in the next few days and try sanding to the prime metal again (this time making sure I do a good job of containing it so that it doesn't spread) and using the the three stage kit.

What do you guys think?

You're passed the point of sanding, you need to grind and/or cut.

See those bubbles in the paint in your pics? That's where the rust has eaten the whole way through, you need to remove EVERY BIT of rust all you'll be right here again next summer, consider an angle grinder or Dremmel tool and cutting out all affected areas then welding in patches. If you don't have access to a welder you MIGHT be able to JB Weld the patches in place, dependsthe backs of those panels look like. Sanding/'rust treater' only works with light surface rust, anything worse needs drastic action.

PS: after sanding/cutting/grinding, use a primer with Zinc added, serious metal work removes the galvanization of the body panels (probablywhy your rust came back) and this will help prevent its return.

[CROYCE992]

OKay. I will then order the Starter Kit and use it to treat all the little areas where I see surface rust. I guess I am going to have to get serious about the other areas. I might actually try cutting out pieces like you said and see what I can do with no welding experience. I am going to have to do some research on the JB Weld product and see if it will hold up.

[933VZFE]

Originally Posted by CROYCE992

OKay. I will then order the Starter Kit and use it to treat all the little areas where I see surface rust. I guess I am going to have to get serious about the other areas. I might actually try cutting out pieces like you said and see what I can do with no welding experience. I am going to have to do some research on the JB Weld product and see if it will hold up.

Do the research and keep in mind there are several different varieties of JB Weld, some may be more suited to the task at hand then others, usually they just require mixing, putting on the piece to be 'welded' and clamped till hardened (clamp on inside of fender, Bondo over recessed area on outside on the 'outside' till smooth). If you can, consider actual welding though, it will hold up better in the long run. I once went to a body shop and just had them cut and weld the rust and finished the job myself (the surface prep and primer/paint is the most expensive part of a rust restore), this may work for you if you don't don't have the experience/ability to cut and weld but can sand and paint.

I recommend you first try this repair on a less visible place (inner wheel well?) or an old junker car before you dive into the body panels, rust restore isn't too difficult but its tricky to catch the hang of at first.

There's some great videos out there if you're interested, try Youtube and Instructables.com.