rust repair

benXJ

Well-Known Member
Joined
Dec 5, 2005
Location
Raleigh NC
I've just encountered some pretty intense rust near the roof on the driver side, right along the A pillar/windshield area. the spot looks very tough to cut and patch, but there are holes through the metal. the largest hole is maybe 1/4in. diameter. besides cutting the rust out, what are my best options? I'm worried that the rust will still be active in spots that I can't see and get to, and will come back.
What I had planned to do was sand it the best I can, get some small craft paint brushes and try and get primer and paint under the edges of the holes. Then get some bondo and body filler and smooth it out, then finish it up with primer and paint. Is that the correct order? I'm going to try and do this tomorrow because of the nice weather and I have the day off. Does bondo have to be applied to bare metal, or is a little primer in spots ok? It does look pretty bad, but I'm really more interested in stopping the progression and then make it pretty later on.
Thanks
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You need to stop the rust first. Primer will not do that. Get some rust stop. There are several different brands but something designed to stop the rust from spreading. Bondo/body filler will fall out in a short time. I advise using fiberglass if you are not going to patch the holes. The ideal fix would be to cut out the bad and replace, but cost time and lets face it amount of work compared to amount of truck sometimes limits that. I suggest the fiberglass and some good rust preventer. Spread the fiberglass thin so you can go over it with body filler to make it easier to smooth out. Good luck and take pics of the process.
 
honestly, if you got rust there, I bet its in alot of different places. I would also bet that the fame of the windshield is also rusty, cause someone put silicone around it to keep it from leaking. If I were you I would just get some of that stuff in a can that turns rust into black primer and clean the area real well with a wire brush and sand paper and spray the entire litte can into the hole and surrounding area. then do a little bondo work and sand some more and finish with spray bomb paint. cause unless you want to keep this rig forever, it wouldnt be worth going all out with cutting, grinding and welding.
also, unless youve done fiberglass before, ya may want to stick with bondo or at least practice with fiberglass before you start. It may just be me but I dont ever seem to get that stuff to work just how I want it.
 
yea...the rust has been a constant issue. i'm slowly dealing with it. I do plan on keeping the truck forever, but it isn't worth much. I also will be taking care of this problem in my apt.parking lot with no welder and few tools. I'm just not sure how to best stop the rust and patch the holes. I was thinking sand, bondo, filler, primer, paint. hopefully that will hold.
 
benXJ said:
yea...the rust has been a constant issue. i'm slowly dealing with it. I do plan on keeping the truck forever, but it isn't worth much. I also will be taking care of this problem in my apt.parking lot with no welder and few tools. I'm just not sure how to best stop the rust and patch the holes. I was thinking sand, bondo, filler, primer, paint. hopefully that will hold.
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well, ya cant stop rust, you can slow it down, but it will still rust. eventually.
 
well removing the windshield and fixing the rust around it is the next thing to do, but for right now I am going to get some spray rust converter, bondo, primer, and paint. Going to try and get up under the affected parts as good as I can. It just needs to last a year or so before I graduate and get a real job and then maybe I can throw some real time/money at it. I'm sure it will come back, but if I can slow it way down, then i'm ok with that. I'm just now sure of the best way to patch the holes. If I use bondo, won't moisture get to the back of it and destroy the work? Is there something better? I've never used expanding foam for car repair...is there a certain kind or brand I should look at?

thanks
 
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