I was working under the 70 last night and noticed 3 very small paint bubbles. Of course we can't have that so I chipped the paint off and began sanding to fix them. Well after getting a 1.5" x1" section of bare metal one of them is an actual hole just large enough to fit one of those parts store freebee screw drivers into. so about 1/8" wide. This section is in the lower quarter that is parallel to the ground, can't see it unless you are looking under the car. And of course where it is located is right inside where all three pieces of metal meet. The quarter, inner wheel well and inner quarter structure. I might be able to get to some of the back side at the very least I know that I can spray something in there. If I stick the screw driver in the hole a rather gooey substance comes out with it, I have no clue what it is. So the real question is how do I repair this. I know the proper way is to weld a patch in but that is not an option the paint on the rest of the car is perfect even though it is 10 years old; I know that putting any heat in there will ruin the rest of the quarter. I was thinking trying to clean the back side painting it with something, painting the outside with something and then filling with body seam sealer and paint over that. The repair does not require a perfect look since it is not a seen area how ever it does require a solid repair that will last. The car is always garaged and most times stays spotless and covered. Although it is very dusty right now. :( I really need some solid advice on this guys you have always been great pleas help. Thanks, sorry for being so long winded.

Tom

Whatever is causing the bubbles and rust isn't going to go away easily. Sounds like the 'goo' you found is somebody's ill attempt at stopping rust. It worked. For a while. Anything short of eliminating the rust and corrosion will only slow the process temporarily. I'm sure you've heard the phrase, 'RUST NEVER SLEEPS'
Sounds like you're going through a phase of denial that it's a simple fix. ;)
If you plan to do a solid repair of the vehicle in the near future, and want to tempararily 'fix' the area, you could attempt a short cut repair by sandblasting, POR-15'ing the affected rot, and then gluing a repair patch with 3M FUSAR. That way you eliminate the heat from the panel.
Blending in the paint will be the toughest part.

Well I know it is not a so called simple fix which is why i want one that is a solid repair. I think the gooey substance is some type of seam sealer or such as used previously. There was never any repair of any type in this panel previous and this is all original sheetmetal, the car came out of Texas and the underbody still has all of the original oxy-primer with no rust from the factory. Bleding the paint won't be an issue since this is on the quarter under the car where it is parallel to the ground only will see it if under the car. Gluing a repair patch would almost be overkill since the hole itself is only 1/8" x 1/16" in dimension. I am thinking i can get to the back side of it and sand as best I can, POR-15 the hell out of it then pain the exterior then show some seam sealer or something through with more paint on that. i am hoping to not do a solid repair for at least another 10 years or so. What is the best materials to use to slow down the rust from returning, and to use as an under paint prep? i know rust never sleeps but it is nice to knock it cold for a few years. I know that if and when the repair needs to be done again I can put a small patch there as no one will see it then. What is the Fusar? Thanks Jimmy

Since you cant weld it, and its basically isolated I would just mix up some JB weld and fill the hole, sand and touch up paint. If you could weld it and have a mig you could probably weld it up with just a few short bursts. Too small for a patch.

I'd spray some POR-15 in from the backside, saturate it good so it gets in all the nooks and crannies and use some sort of filler from the front and spot that area in. If the car is kept inside and out of the elements I'd bet it would hold for a good long time. Be carefull if you would decide to mig it, the surrounding area is most likely thin and you could easily burn through and end up with a hole twice as big.

Well after actually calming down and looking at it last night the gooey stuff is a type of body seam sealer they used from the factory to coat teh insdie of the panels. It was all along the floor edge between the inner and outer quarter. After removing a couple inchs of this and the foam that they used between the body panels i could get a good look at the culprit. If GM had been a little smarter in their design I wouldn't have the issue. Basically there is a drain hole parallel to this one just on the other side of a small lip from the metal pieces joining, so water would stick in this very small corner and sit. After cleaning everything out in the corner where the hole is I was amazed to say the least. Sans for 1/64 of an inch around the small hole, all of the metal is perfect with no bubbles and the original primer still on it. I am thinking what I will do is finally finish off my complete trunk since I kept putting it off. I will have to sand real good in this area to make sure everything is perfectly clean, por-15 the inner side real good, paint the outer side, and fill in the little hole with some seam sealer and final paint. With as awesome as the back side looks, it appears that this hole was one of those freak location ones, like it might have been thin on coating fromt eh factory and after all those years of holding dirt and moisture it was just time to come out. i figure I should be able to fix it up real good with no issues coming up later. I almost considereed drilling the hole slightly bigger and leaving it as a drain hole, but i don't think that it would sit right with me later on. More advice is welcome, i should try to get some pictures of this so people can see. The hole in the middle of a perfect coating had to be from a low spot there inside that is the only thing i can think of since the water and crud couldn't move around to the other side of the lip. Thanks