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Old 10-16-2020, 07:36 PM   #1
skwrl
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Member#: 359878
Join Date: Jun 2013
Default Need help assessing rust.

Hey guys,
I'm newb at metal work and I've found some rust on my 02 bugeye after taking up the carpet.
At what point does the metal have to be replaced (cut out and new metal welded in)?

This is right behind the front passenger seat. I've wire brushed a good amount away and you can see it's quite pitted but it still seems solid. I've seen youtube videos of people replacing panels looking less damaged than this though.

Is this amount okay to just spray down some rustoleum rust reformer and paint over it? (or should I use POR instead?)

There's rust on driver side as well.


Just need a benchmark / gauge of when I should be considering replacing metal.

Thanks!
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Last edited by skwrl; 10-28-2020 at 08:59 AM.
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Old 10-18-2020, 12:54 AM   #2
basyager
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2019 WRX

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Quote:
Originally Posted by skwrl View Post
Hey guys,

At what point does the metal have to be replaced (cut out and new metal welded in)?

Thanks!
When the seat starts rocking back and forth

Your car looks solid. Rustoleum and a little grease on it.

I had a 2005 corolla and its floor had holes about 1 inch in diameter with rubber grommets installed. But on mine of the grommets was missing. Soundproofing material got soaked in the salty road slush and not drying out for the whole duration of winter it just accelerated the rust by 5000%
I took off the carper and saw this mess and ended up replacing a large chunk of passengers floor. Everyone made fun of it saying its a flintstones car.

it was a pain in the ass and not worth it but it was fun and I got to buy a welder

I ended up selling that car a few months later for $600 to be cut up and sent to africa.

Last edited by basyager; 10-18-2020 at 01:03 AM.
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Old 10-22-2020, 10:30 AM   #3
dr.andras
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I'm currently looking at a 2004 STI with some rust already, slightly concerned it's worse than I think it is.
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Old 10-26-2020, 07:01 AM   #4
Felonin
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Omg, i've had the same situation
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Old 10-27-2020, 04:32 PM   #5
skwrl
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Thanks, I feel a little better about the rust now.

I went ahead and hit the rust spots with an angle grinder and wire wheel, wiped with acetone, covered with JENOLITE rust converter, sprayed with Rustoleum rust reformer-- and now a week later, I have this weird beading rust coming up in places. It's like little beads of wet rust, kind of greasy feeling.
I've had this happen in other spot of the car where I tried using Rustoleum automotive spray paint before but I figured it was because I didn't correctly prep the surface and the paint wasn't for rust.

This is where driver seat bolts in, behind the fuel door lever. Hard to get an angle grinder in there, and I'm not ready to remove that cross member from the floor (to get the rust beneath it).



What is this??
Is it because of high humidity? I live in FL and had a small puddle of water in my garage that refused to dry up over an entire week until I wiped it off with a towel...
Or is it because I didn't remove enough of the rust?
Suggestions how to get at tight corners like this with power tools?

Last edited by skwrl; 10-28-2020 at 08:59 AM.
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Old 10-27-2020, 08:50 PM   #6
Vancouver98STi
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Location: Vancouver BC Canada
Vehicle:
1998 JDM Impreza STi
V4 GF8 White

Lightbulb When posting images...

Just a suggestion... it would be a whole lot easier viewing images if they were embedded into your posts. Try using NASIOC's image host Here. It's quick and painless.
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Old 10-28-2020, 10:03 AM   #7
skwrl
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Thanks. Updated the images!
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Old 10-28-2020, 04:23 PM   #8
Vancouver98STi
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1998 JDM Impreza STi
V4 GF8 White

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Quote:
Originally Posted by skwrl View Post

I've found some rust on my 02 bugeye after taking up the carpet.
Did you have an issue with with rainwater somehow leaking into your car, and then perhaps soaking the carpet's underfelt... and ultimately rusting the floor?

When I went to look at the GF8 that I now own, I asked the previous owner to have a look under the rear cargo area cover. When he lifted the cover to expose the spare tire compartment, I couldn't believe my eyes. The car had obviously been outside in the rain for awhile... and the spare tire tub was full of water to the top! I asked the owner if he kept goldfish back there. Despite this issue, I ended up buying the car... although yes, the water infiltration problem helped to get the price down. Fortunately, the water hadn't been making its way into the passenger/carpeted area of the wagon, and thankfully there was no interior rust.

Last edited by Vancouver98STi; 10-28-2020 at 04:58 PM.
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Old 11-02-2020, 11:07 AM   #9
Wayne Suhrbier
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2006 STI
OBP

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For tight spaces rifler files are great. Can be a good excuse to buy a dremmel also. Humidity can mess with a lot of paints, coating, ect. You'll hit the same problem I have in that there are maybe three days a year that the humidity is low enough to be within the recommended limits. If it doesn't need a toxic solvent I try to avoid it.
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Old 11-02-2020, 02:20 PM   #10
WhiteZombie
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PSM 05 WRX WGN 5MT
95 Caprice 6spd Track Rat

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Quote:
Originally Posted by Vancouver98STi View Post
The images embedded in your posts are now much easier to access and view!


Did you have an issue with with rainwater somehow leaking into your car, and then perhaps soaking the carpet's underfelt... and ultimately rusting the floor?

When I went to look at the GF8 that I now own, I asked the previous owner to have a look under the rear cargo area cover. When he lifted the cover to expose the spare tire compartment, I couldn't believe my eyes. The car had obviously been outside in the rain for awhile... and the spare tire tub was full of water to the top! I asked the owner if he kept goldfish back there. Despite this issue, I ended up buying the car... although yes, the water infiltration problem helped to get the price down. Fortunately, the water hadn't been making its way into the passenger/carpeted area of the wagon, and thankfully there was no interior rust.
My GF8 was like that too. Not sure where the water was getting in, as it was a rusting 230k mile daily beater, but poking a little drain holes in the rubber plug at the bottom helped empty it out quicker at least
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Old 11-02-2020, 04:30 PM   #11
Vancouver98STi
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Member#: 459287
Join Date: Dec 2016
Chapter/Region: VIC
Location: Vancouver BC Canada
Vehicle:
1998 JDM Impreza STi
V4 GF8 White

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Quote:
Originally Posted by WhiteZombie View Post

My GF8 was like that too. Not sure where the water was getting in, as it was a rusting 230k mile daily beater, but poking a little drain holes in the rubber plug at the bottom helped empty it out quicker at least
The owner of the GF8 that I was looking at had no idea there was a rubber drain plug in the bottom of the spare tire "tub". When I reached down and removed the plug, quite a tsunami was created!
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Old 11-02-2020, 07:18 PM   #12
skwrl
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Default

Quote:
Originally Posted by Vancouver98STi View Post
The images embedded in your posts are now much easier to access and view!


Did you have an issue with with rainwater somehow leaking into your car, and then perhaps soaking the carpet's underfelt... and ultimately rusting the floor?

When I went to look at the GF8 that I now own, I asked the previous owner to have a look under the rear cargo area cover. When he lifted the cover to expose the spare tire compartment, I couldn't believe my eyes. The car had obviously been outside in the rain for awhile... and the spare tire tub was full of water to the top! I asked the owner if he kept goldfish back there. Despite this issue, I ended up buying the car... although yes, the water infiltration problem helped to get the price down. Fortunately, the water hadn't been making its way into the passenger/carpeted area of the wagon, and thankfully there was no interior rust.
Definitely have that problem too. I located the leak to a seam under the rear windshield in the runoff channel toward the right side where two body panels come together. I had a bunch of debris and dirt build up there too causing water to sit in the channel. Cleaned it out and have yet to figure out how to stop the actual leak.

On a long road trip, my ac condensation tube dislodged itself somehow and was draining into my passenger's footwell, flooding the entire right side of the car. It looks like whoever worked on the car before cut up the tubing here and there and was zip tying pieces wherever they needed tubing so my drain tube barely extends out of the firewall. smfh.

Pretty sure at one point the driver window was left open too, at one of the NE shops I wont mention, and the driver door card is stained and there's a bit of rust under the passenger seat too.

Found more spots where rust is bleeding through the converter I put on. I used an angle grinder and went at it with a wire wheel. I wonder if it wasn't enough to actually remove the majority of the rust, or if it's just too humid when I applied the converter?
Kind of worried how this will affect the rest of the areas I tried to clean up...
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