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Rust repair


Bax03SE
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I did this project in the summer, but just now decided to post it. Like many, my 03 had some rust creeping out from behind the fender flares in the back. Just like an iceberg, what you see on the surface is usually just a little taste of what’s lurking underneath. I decided the best course of action was to cut out all the bad metal and rebuild that section with fiberglass. I used fiberglass cloth and resin for the basic structural repair, then finished it off with tiger hair and body filler. Since this was a small project I decided to try 2k clear coat in a can for the first time, and I was very pleased with the results. It laid down nicely and was easier than getting out my compressor and spray gun. I lined the portion of the paint that is hidden under the flare with bedliner to help protect it in the future, so that’s why the paint at the edge of the wheel well looks a little rough in places. It isn’t visible with the flare back on.

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Very nice work. I had to do the same thing to my 96. Drivers side rear below and to the right of gas tank lid continuing on to the rear pass drivers side threshold. Pictures 2 is the finished product .63c009067b0dee37dba8588b6d968375.jpg9bc4ee58f5a611964c490e890066b1b5.jpg

 

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17 hours ago, Bax03SE said:

 

I did this project in the summer, but just now decided to post it. Like many, my 03 had some rust creeping out from behind the fender flares in the back. Just like an iceberg, what you see on the surface is usually just a little taste of what’s lurking underneath. I decided the best course of action was to cut out all the bad metal and rebuild that section with fiberglass. I used fiberglass cloth and resin for the basic structural repair, then finished it off with tiger hair and body filler. Since this was a small project I decided to try 2k clear coat in a can for the first time, and I was very pleased with the results. It laid down nicely and was easier than getting out my compressor and spray gun. I lined the portion of the paint that is hidden under the flare with bedliner to help protect it in the future, so that’s why the paint at the edge of the wheel well looks a little rough in places. It isn’t visible with the flare back on.

f62365ba02a3c1ab23fef928dd84008b.jpg77c13814a2ea8b38a89839dc1bc8ab5d.jpgc3521ffd4849511db2ed5512db054edc.jpg22af61c6b8b401662441a26bfd4b91b1.jpg3d3042e7458f3788d62bf61f05523354.jpg9f6ea0a69bfabb4c2e2ef96d9178edfc.jpgf85ef1cc4528b5fee16480c254b406cb.jpg

 

 

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That looks really good. What did you paint it with? 

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This was just a quick and inexpensive project, so I used duplicolor products for the primer and base coat. Then for the clear I used a 2k clear in a can. It is a two part high solid urethane clear that comes in a spray can. Before you spray it you flip the can over and push it down on the included adapter that releases the hardener into the can to mix with the paint. Once the hardener has been combined you have about a 48 hour window to use the can before it is no good. This is the first time I’ve tried this product and the final result was every bit as good as traditional clear coat that I would usually apply with a gun and compressor. 

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12 minutes ago, Sjackson2 said:

Interesting. Did you have to do any buffing or blending of the clear coat afterwards? I have some pretty bad clear coat oxidation on my hood that would be nice to fix 

If you look at how I masked it off, I used the body line as a cut off to mask from, so it hides the cut off where I sectioned off that part of the panel for paint. The only buffing I did was to the old paint surrounding (upper section of quarter panel, the rear bumper, and the back door) the freshly painted section so it wouldn’t stand out as as too shiny compared to the surrounding paint. I didn’t do any sanding or buffing on the new paint.

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  • 4 weeks later...
Interesting. Did you have to do any buffing or blending of the clear coat afterwards? I have some pretty bad clear coat oxidation on my hood that would be nice to fix 

When I done my rust repair I had no idea about buffing the clearcoat when finished. It look like crap and my Dad told me I needed to buff it and it should bring the clearcoat out. It done wonders. Like night and day.

 

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