Rustproofing continued-rot found :(

[navajoninetynine]

I figured I should avoid clogging up the 'what did you do to your Aurora today' thread. You may have seen my posts about the bodywork done on the driver's rear quarter.

Today I went to tackle the driver's rear door near the front bottom corner. Started off well enough!

Sanded down to find just bare metal. Easy, right?

I got curious and pulled off the quarter panel cover.

I found this:


I had hoped some of that was just surface bubbling, but after some brushing, it looked like this:


I don't see how that could possibly be fixed without a donor car from out West, pulled from a garage for a dry rocker/body/wheelwell section. I've cleaned it up a bit more and applied Permatex rust stopper and whit Rustoleum for now. Any ideas on what more I can do on a budget? I'm betting the other side looks the same.

[sall]

POR15

www.por15.com/POR-15-_p_8.html

[navajoninetynine]

Sept 8, 2013 20:31:23 GMT -6 sall said:

POR15

www.por15.com/POR-15-_p_8.html

Heard of that, but what can that do with the rot thats INSIDE that section? I can't get to it.

[dogora]

Do you have access to a welder?

[navajoninetynine]

No welder/tools, or a good chuck of car, or the knowhow (yet.)

[nelson480]

Problem is its rotting from the inside out. You wont stop it unless you cut out and replace that section. But if you plan on driving this car in the salt, it will never stop rusting. Rockers go, floor pans go, strut towers go, unibody goes... cant stop it totally lol

[navajoninetynine]

Well, I DID find something on gmpartsdirect that could be an answer. Full-blown new rockers, with extensions, $45 per side plus shipping. How hard are they to cut out and replace? Or would tearing out the old destroy the car?

[nelson480]

Is it the front cap? Its not a bad job if you can weld.. but imagine what lies inside that sealed chamber that is the rockers..

[navajoninetynine]

Sept 11, 2013 21:37:04 GMT -6 nelson480 said:

Is it the front cap? Its not a bad job if you can weld.. but imagine what lies inside that sealed chamber that is the rockers..

I can't weld (yet,) but its the rear extension.