I didn't get all the rust covered. I have a rust problem along the bottom of the driver side front fender just in front of the door. I have no welding ability and not much money but this rust problem is driving me crazy(er).

Anyway, over the past year or so I have sanded and repainted this spot at least six times. I've used various rust inhibitors, including, the last time, POR. After a month or so the rust reappears as little pimples under the paint. I understand it might not be possible to stop the rush without cutting out the metal but since that's outside my expertise I'm gonna give cleaning, sanding and repainting the area one more try. Any suggestions on anything special to try that might help me be successful this time?

There is a litttle bondo in the area now because I sanded through trying to get rid of all the rust.

To get it fixed right I'd have to take it somewhere and have the area cut out and new metal welded in. Any guesses on how much this would cost?

Thanks smile.gif

I'd buy a fender patch for that area and have it welded in and painted/treated properly. NPD has them for $40 each.

The moisture is going to still wick through from the backside and continue to rust the metal, thats why none of your repairs have held so far. The best repair is to have that section replaced.

Ask a couple of body shops to give you an estimate, I wouldn't take it to the first place you find, shop around a little.

What POR didnt work!!! I thought that stuff killed rust stopped it dead in its tracks, plus its hammer tough?

Sorry but theres NO replacement for PROPER prep and metal replacement.
Man I should gather up that tree sap from that evergreen in my backyard a sell just like POR does

Panel replacement would be best, or having a welded in patch installed would be another option. Or, If the area is small I think you could do this with adhesive. Fitting the patch perfectly before installation is critical when using adhesive as there is no moving it after the cure. Check out Fusors website for instructions-this may be the route for you if a welder isn't available. Just an idea. Bob

With No $ and the fix out of the CAN did not work.. there is only ONE permanent fix, cut out and weld in NEW steel.. But having worked in a Shop who #1 business was used cars, I know a few down and dirty short term fixes..Grind the area 36/ or 80 grit clean of paint and surface rust.
Take your body hammer and knock the area LOW at the rust and extend beyond.. using the pick end.. knock out as much of the rust as you can,, mix up a mess of fiberglass reinforced Mud.. ( tiger Hair- Grolia Hair- Kitty Hair )A cheeper way is to use steel whool or Silver flashing tape( yes I have done that ) and regular BONDO.. slap it on.. sand and conture to shape.. rattle can primer. then what ever rattle can color you want.. It will not last for ever.. One year if your lucky B-4 you see the dredded Bubbles.