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Registered
Join Date: Dec 1969
Location: East Windsor, NJ
Posts: 22
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When you say some "subsurface rust that is starting to bubble" (sail panels), do you mean in the seam between the sail and quarter? Also, do you still have the vinyl covering the sail or has it been stripped off and painted? The reason I ask is because the seam always seems to rust out - and the tell tale sign is the "slight paint bubbling". Trust me, if its bubbling there, its only going to get worse (probably soon). The original chrome piece that went below the vinyl popped into a series of little holes that are typically filled and painted over when the vinyl is removed - usually leads to probs.
I guess the only answer is (a) live with it for now or (b) start stripping the entire area and see exactly what you're dealing with. If any kind of body work or rust repair was previously done there, it could be time to re-do it (especially if it wasn't done right the first time). I've done the repair before using the replacement sail panel (full one that comes down to the door handle) and door post (where the latch goes). I didn't replace the whole thing, just cut out the pieces I needed and welded them in - you may even be able to just fabricate your own pieces depending on what you find and where exactly the rust is (and how good you are - the curves can be tricky to fabricate).
I know - "strip it and see" aint much help, but that's what it usually comes to sooner or later when you're talking about rust/paint bubbles. Good luck!
-Paul
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