I picked up a RAV4 back in December, 181K miles, runs really good, replaced the struts and sway bar links, new brakes and tires, handles very well, especially in snow and everything works. There is a paint scuff on the right front bumper and fender that looks like it will buff out and otherwise is dent free. The one body part that is bad is drivers rear quarter above the wheel well and arch to rocker in front of the wheel. It is bubble pretty good but still feels solid. Ill post a couple pics later when I can sync the phone.

So those who are into body repairs, would you buy a new quarter and cut out the section? I can probably get a used California quarter and have it shipped, or a new one, the used would be $400 the new about twice that. The majority of the quarter is 100% sound, its just the lower part. My other option is make new pieces to fill in the bad spots and use Rust Mort and body filler. An alternative is finding a wrecking yard near me that will let me cut out the piece I need if I can find one. I think 06-15 are the same, the only difference is if it has flares or not. Mine is flare free, the one with flares has holes for the clips and might have an indent for the flare.

 

Well I dont know what your skill level is or what equipment you have to work with so hard to tell you how to go about this repair.
I cant see spending big bucks for a new or even a use panel so that leaves either finding patch panels, have you looked for any and not the full panel? or make what you need from sheet metal.

Also know what you see there the rust goes out a lot more from there and will need to be cut out to stop it from coming thru again.
Once opened up you will find more rust on the inner panels and will need to be dealt with if not rusted thru already.

Then again you could grind the area, knock it in a little and fill it with mud (body filler), sand prim & paint.
Dave ----

 

The easiest answer is that it's in a good spot to cut it out and replace. Can you make that sheet metal, sure, even with basic hand tools but IMHO if you can find a scrapyard that will cut out what you need... that's the way to go! IMHO, I would also get some scrap metal because when you cut that out and see underneath you are probably going to have some other work to do.

 

I agree with others here. there is more going on then what you see. Find a panel if you want but there is more rust there then you see. Kind of like an iceburg only about 10% is above water. I would look for a complete panel but once you cut you will be buying more parts and pieces.

 

Funny thing is, behind it, the inner well has zero rust on it. I am fairly certain that this is bleed through rust that started from the inside from a poor adhesion. Like what happens with the ram box fenders where they stuck foam between the inner well and side and trapped moisture and salt, causing massive rust. The inner panels and outer panels are secured with adhesive before being spot welded. Due to the location of the rust, this is what I am thinking happened here, that it seeped in between the inner and fender and attacked the outer panel. This panel runs all the way down and has about 4 inches of horizontal before connecting to the main rocker. It still seems fairly solid, but until I take a body hammer to it, won't know if its a full through rust, or just surface, which I doubt.

Come spring I will check out my local yards to see if I can get a clean section from them. If not, I have a friend with a french wheel and can form some parts for me.

 

Here are a couple videos that may help you out.

 

Surprising enough it must a problem as you pointed out with structural foam the manufactures use trapping moisture in the long run. Repair panels are available, bone yards probably will not yield a good solid panel. Ford Escape exhibits the same problem over the rear wheel well.

 

The interesting part is that just the drivers side has it, the rest of the car is clean. It is definitely trapped salt water though as a little piece popped out and it is clean through to the inner fender, which is actually rust free. Since Toyota, being Toyota, hasn't changed the RAV 4 body style for several years, later MY panels will still fit, so might find a later MY that is still clean. If not, I will just have to fabricate pieces and stitch them in.

 

Driver side is the Salt side and if the previous owner never kept the vehicle washed, they rust pretty bad. I can make panels but if one is offered, saves the time searching bone yards, then wait for Big Brown truck to hit my driveway. Depends if your intention is to flip or keep for repairs, Clean Car Carney flippers are out there.

 

It's my Daughters first car, so want it to last a few years. It has 183K on it, needs the rear differential clutch thingamabob, the name escapes me at the moment, replaced, and new rear shocks, which are a PITA to replace, but otherwise drives great. She is driving on permit at the moment, so a few more months before she can take her test to get the license. In the meantime my wife and I have been driving it all over the place rather than her Focus which is due for the dual clutch replacement, again, and the costly F-450. I only paid $2K for it and put on a new set of tires and struts/shocks, Toyota did a bunch of recall work on it too. Spunky little bugger too with the V6. It was my SIL car, she bought it when new and kept it washed and garaged, but it still got salt rash.