need help with rust - Diesel Forum

normanpaul · 02-23-2009, 04:23 PM

Both of my rear fenders are rusting out from the inside. I got out the sand paper and went to work and the rust is coming from between the two pieces of sheet metal the outer and inner fender just above the wheel, and there is some type of body filler or foam of some sort between the two pieces of metal. Has any one had this same problem. My truck looks to good to just let it rust out and fall apart now I plan on keeping this truck for a long time. My plan is to do as much as i can and then go to the body shop for some patch work. Any ideas

BTBBT · 02-23-2009, 05:41 PM

My truck is doing this too. Short of completely removing and replacing these sections I don't know what to do. I even took it to a body shop and wanted it fixed. I thought it was due to a botched repair but they said it was common to the trucks. They never did offer fix it. How stupid to turn down a chance to make money?

korg70bc · 02-23-2009, 05:54 PM

Have u heard of these products? Eastwood Rust Treatment: Rust Removal, Prevention & Protective Gear I watched a show on metal & how rust is still steel, just sick. SO I think this product has it down. It can be stopped & sometimes reversed.

normanpaul · 02-23-2009, 06:16 PM

Hey thanks for the reply's. I already have a pretty good size hole in the drivers side so I am going to need patches. I was thinking someone would tell me where I can gain access to the problem area. My thinking is if i can get rid of what ever is holding the moisture in there and fix the rust I might be able to keep it from happening again. I only have 109,000 I am not giving up on this one yet. Even if I have to cut up the inner fender to get all that stuff out of there I guess I will.

BTBBT · 02-23-2009, 09:33 PM

I think access is the whole issue here. That's why they rust out, there really isn't a good way to get in there. Problem is that since Ford can't really get in there when they dip the whole bed in a tank... we the simple public have even less of a chance to get in there to stop it. The best option I can think of is that Eastwood product if there is a way to spray it up between the inner and outer fender and dissolve the rust. The next trick is to get something in there to keep it from happening again. This brings me back to the fact that if Ford can't get enough up there to keep it from rusting, what can we do? Now, seeing as you have holes, removing those areas may get you a little better access... maybe.

I would check into the Eastwood stuff. I know they make good products, though I have not used any myself.. yet. Sounds like I may have to start soon myself.

nasty50 · 02-23-2009, 10:54 PM

rust is basically cancer of an automobile. you can cut it out but if not done properly or if contaminated metal isnt cut out guess what, it comes right back. The best way, not necesarily the cheapest way to fix is to have the bedside replaced. once the side is removed then corrosion protection such as an etching primer can be applied to help prevent rust. The foam like stuff you see is basically that -rubberized foam. It is supposed to help with vibration and the hollow sound, but it works better to hold moisture. Normally when I replace a bedside on a ford,I remove all that foam and put sound deadening pads on the backside of the new panel to help with the hollow sound. gm doesnt have it in theirs- see any rust? It is expensive to have this done so dont be surprized when you get an estimate. Make sure that you tell them to put weld thru coating on, if that isnt done then everthing was wasted time and money. Just remember the dealership is not always the best place to go. It is just a body shop that happens to be owned by the dealership-they are not better than anyone else. It is the individual tech that does the work that makes the difference. I am a body tech myself. hope this is somewhat helpfull to someone.

nycpsd · 02-23-2009, 11:32 PM

I have the same problem (Just have to find the time to fix it. looks terrible) and I agree with Nasty50, surface rust and flash rust are not so much of a big deal a little sand paper phosphoric acid and a good weld through primer and your set bring it to the shop and have it painted, but rot is when it starts to flake and you can put your finger through it on either side you will notice the carnage this is where you must cut out the bad and replace with new, nice to at least know your sailing with someone else.

fordsforever73 · 02-24-2009, 12:51 AM

I'm restoring a '90 Bronco. It has the same issue (as they all do around here). So I cut two holes from inside the truck using a 2" hole saw. I cut both holes side by side just above the wheel well and that gave me lots of access to the rust area. It was full of dirt/sand/rocks, so I blew it out with compressed air. Next I will make both holes into one so that it is basically an oval hole 2"x6", then I'll paint the inside (after welding patches in where the rust is on the outer panel) with POR 15...awesome product. I used this on everything from the floor down to the ground. Then I'll make some nice covers to go over the inner fender hole that will give me access to wash out that area in the future.

normanpaul · 02-24-2009, 08:12 AM

thanks for all the input folks very helpful I need to ask around for a good body tech. I have always wanted to change the color of this truck anyway. I will let you know how it turns out.

**my03psd** · 02-24-2009, 08:03 PM

The problem is from the foam sealer they use.It holds water and never gets to dry out thus rusting from the inside out.

Ro39 · 04-03-2009, 05:00 AM

Im getting the rust too. What about drilling holes under the fender so water/moisture wont want to stay?

-Desperate