RUST!!!!!!!!!! UGH!
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
OK, got some more pics! I got the backside of the rockers all sanded and undercoated. I`ll get that pic later.
Here is the new rocker panel. I already cut it down to fit with the holes where they need to be. I shortened the rocker about 4 inches.
Here is the painted rocker. the color is a perfect match!
This is the panel bonding adhesive. made by 3M. if you put some heat to it like a heat gun or space heater it will cure the adhesive in a half hour.
As soon as I wake up here I`ll get out there and start getting it glued on. I still have to finish undercoating the other rocker panel on the pass side. I did put some cutout in that side also to check out the inside and it is no where near as bad as the drivers side was! I did put some DOM16 on the rust and I need to epoxy coat the inside of the rocker still. once I do that I am going to disassemble my running boards, clean the rust from the brackets and coat them with the DOM16 too.
Here is the new rocker panel. I already cut it down to fit with the holes where they need to be. I shortened the rocker about 4 inches.
Here is the painted rocker. the color is a perfect match!
This is the panel bonding adhesive. made by 3M. if you put some heat to it like a heat gun or space heater it will cure the adhesive in a half hour.
As soon as I wake up here I`ll get out there and start getting it glued on. I still have to finish undercoating the other rocker panel on the pass side. I did put some cutout in that side also to check out the inside and it is no where near as bad as the drivers side was! I did put some DOM16 on the rust and I need to epoxy coat the inside of the rocker still. once I do that I am going to disassemble my running boards, clean the rust from the brackets and coat them with the DOM16 too.
Thread Starter
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
OK, made some progress.
This is what I got done earlier in the week. I cleaned and undercoated the back side of the passenger side rocker panel. I thought I had a picture from after I put the DOM16 on the rust but I guess not? I did take a picture of the other side before the undercoating!
Here is the after. I scuffed everything really good so the undercoating can "bite" into something so it doesn`t peel off. Yes I need to clean up the frame. fortunately that is only surface rust and can easily be scraped and coated.
A note to everyone. that crossbrace in the middle (where it is welded to the rocker panel) has no way of letting anything out. it was filled with dirt/sand and debris. I`m really surprised this wasn`t rusted out. I think the reason it wasn`t is because it has airflow and it can dry out, unlike inside the rocker panels that stays damp and has no airflow.
And here is the panel attached. I have an electric space heater on it to speed up the curing time.
I`ll get a finished picture after the adhesive is cured.
This is what I got done earlier in the week. I cleaned and undercoated the back side of the passenger side rocker panel. I thought I had a picture from after I put the DOM16 on the rust but I guess not? I did take a picture of the other side before the undercoating!
Here is the after. I scuffed everything really good so the undercoating can "bite" into something so it doesn`t peel off. Yes I need to clean up the frame. fortunately that is only surface rust and can easily be scraped and coated.
A note to everyone. that crossbrace in the middle (where it is welded to the rocker panel) has no way of letting anything out. it was filled with dirt/sand and debris. I`m really surprised this wasn`t rusted out. I think the reason it wasn`t is because it has airflow and it can dry out, unlike inside the rocker panels that stays damp and has no airflow.
And here is the panel attached. I have an electric space heater on it to speed up the curing time.
I`ll get a finished picture after the adhesive is cured.
Thread Starter
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
And since I`m covering X rust issues....I`ll post these too! I thought I posted them back then, but I guess not. they weren`t in my photobucket. I did this about 2 1/2 years ago and they still look like the finished outcome here and show no signs of popping any rust!
This is what I started with. BTW the X had 60k miles when I found this.
I ground all along the lower lip of the door, it was bad enough I had to cut some of the lip of the outer door skin that folds over the door frame!
After I got rid of all the rust I used some POR 15 for this. and I also coated the inside lower door heavy with it. this let it migrate down into any rust or openings that let rust start.
Then I taped off to the space just behind the weather strip that runs along the bottom of the door.
This is the finished product. with the weather strip reinstalled you can barely tell I did anything. all you see is the line at the end of the door.
This is what I started with. BTW the X had 60k miles when I found this.
I ground all along the lower lip of the door, it was bad enough I had to cut some of the lip of the outer door skin that folds over the door frame!
After I got rid of all the rust I used some POR 15 for this. and I also coated the inside lower door heavy with it. this let it migrate down into any rust or openings that let rust start.
Then I taped off to the space just behind the weather strip that runs along the bottom of the door.
This is the finished product. with the weather strip reinstalled you can barely tell I did anything. all you see is the line at the end of the door.
Bleed Ford Blue
Joined: Apr 2009
Posts: 13,578
Likes: 157
From: Anchorage Alaska
i'm astounded by the rust issues you guys in the salt laying areas go through. if something as new as a 2002 was rusting i'd be very upset.
work looks good though! hopefully you have slowed the progress greatly.
work looks good though! hopefully you have slowed the progress greatly.
Elder User
Joined: Jan 2012
Posts: 777
Likes: 2
My Ex will be going through similar rust fixing/prevention soon since it's been very well taken care of before me and I've neglected it for the past 2 winters
Bleed Ford Blue
Joined: Apr 2009
Posts: 13,578
Likes: 157
From: Anchorage Alaska
lol... foreman at work has a 2010 Jetta that is starting to rust. You have to get your vehicles undercoated religiously around here and wash them off every chance you get.
My Ex will be going through similar rust fixing/prevention soon since it's been very well taken care of before me and I've neglected it for the past 2 winters
My Ex will be going through similar rust fixing/prevention soon since it's been very well taken care of before me and I've neglected it for the past 2 winters
Rock chips and muddy road spray are my only concerns with winter driving (well more like fall/spring)
Thread Starter
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
lol... foreman at work has a 2010 Jetta that is starting to rust. You have to get your vehicles undercoated religiously around here and wash them off every chance you get.
My Ex will be going through similar rust fixing/prevention soon since it's been very well taken care of before me and I've neglected it for the past 2 winters
My Ex will be going through similar rust fixing/prevention soon since it's been very well taken care of before me and I've neglected it for the past 2 winters
Here is one of the doors I fixed 2 1/2 years ago. still holding up! I did the other 3 the next spring, although they were no where near as bad. at work we find these issues with GM cars/trucks too.
Logistics Pro
Joined: Jan 2011
Posts: 4,892
Likes: 3,452
From: Ohio
I need to do that door thing to my wife's car. It's a 2008 and it gets a once a week bath religiously. Yes, the rust belt sucks, thus my EX gets parked for the winter.
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Thread Starter
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
Well here is the finished result.
What a PITA! but i'm done. I used some rust fighter in all the cavity's to keep the surfaces from rusting. This is the stuff i should've used when i first bought the X.
Now i need to reinstall the running boards. But first i am going to clean up the rust on the brackets. Might as well do a 100% job!
What a PITA! but i'm done. I used some rust fighter in all the cavity's to keep the surfaces from rusting. This is the stuff i should've used when i first bought the X.
Now i need to reinstall the running boards. But first i am going to clean up the rust on the brackets. Might as well do a 100% job!
Elder User
Joined: Jan 2012
Posts: 777
Likes: 2
Damnit... I just pulled the rubber plug from mine and stuck my finger in... about an inch deep... into wet mud/calcium/crap.
Guess I'll have to pull mine off and check them once the weather comes around.
Predicting about 5 degrees for the rest of the week and -5 at night. Not sure we're getting a spring this year
Guess I'll have to pull mine off and check them once the weather comes around.
Predicting about 5 degrees for the rest of the week and -5 at night. Not sure we're getting a spring this year
Hotshot
Joined: May 2005
Posts: 13,484
Likes: 42
From: Stevens Point, WI
Last time I looked my door were holding up great yet after the repair as well.
I did the repair when I first got the X.
First page of the "What did you do to the X" thread. https://www.ford-trucks.com/forums/9...e-x-today.html
I did the repair when I first got the X.
First page of the "What did you do to the X" thread. https://www.ford-trucks.com/forums/9...e-x-today.html
Thread Starter
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
Jayjjcc, yes get that taken care of right away! Do you have any rust showing yet?
Snowseeker, that rust on the door looks just like mine did. Gotta, keep these trucks alive!
Snowseeker, that rust on the door looks just like mine did. Gotta, keep these trucks alive!
