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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; Today at 08:59 AM.
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Old 10-18-2020, 12:54 AM   #2
basyager
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Default

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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Default

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 Yesterday, 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; Today at 08:59 AM.
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Old Yesterday, 08:50 PM   #6
Vancouver98STi
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Join Date: Dec 2016
Chapter/Region: VIC
Location: Vancouver BC Canada
Vehicle:
1998 JDM Impreza STi
White GF8 wagon

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 Today, 10:03 AM   #7
skwrl
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Thanks. Updated the images!
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Old Today, 04:23 PM   #8
Vancouver98STi
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Join Date: Dec 2016
Chapter/Region: VIC
Location: Vancouver BC Canada
Vehicle:
1998 JDM Impreza STi
White GF8 wagon

Question

The images embedded in your posts are now much easier to access and view!

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; Today at 04:58 PM.
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