Weird rust
 

Hi all,
On my recently purchased 1989 Carrera there is a (dare I say it) a 1 inch rust bubble on the right side panel directly behind the side window. Has anyone else encountered rust like this on their 911 whatever the age and if so can anyone tell me what may have caused it. There is not one speck of rust on the car anywhere else (it is a ROW ex Germany then Japan and now Australia). I thought it may have originated because of the sunroof drainholes being blocked but after shoving some stiff plastic weed whacker line up there they don't seem to have been blocked badly. thanks in advance Markhttp://forums.pelicanparts.com/uploa...1142158517.jpg

I'll try again
 

first time the pic came out black, let see if this workshttp://forums.pelicanparts.com/uploa...1142159601.jpg

resize it to a smaller picture and it should show up.

one more try
 

here goeshttp://forums.pelicanparts.com/uploa...1142235714.jpg

Is that what they mean when they say a car is "triple black"?

Keep trying.

this is ridiculous
 

I re sized it twice in photoshop and the original was small.http://forums.pelicanparts.com/uploa...1142333242.jpg

yeehah
 

so guys what do you think?

That is diffinently an anomaly. I've never seen that in terms of the usual places you find rust. My guess is that there was a contamination of some sort when the car was painted.

just have it touched up.

Only way to discover how bad it is is to have a poke with a sharp object and see if the metal's intact or rotten under the paint.
Not nice but only way I'm afraid.

Does that area have any foam sound deading insulation behind it?

I know that the 70's VW bugs would rust from the inside in the are beahind the rear quarter windows due to moisture being soaked into the insulation foam like a sponge and 20 years later the rust would start to show..

John

On 911's the 'C' pillar is closed up unlike the VW.

Some thoughts.... you say you used some nylon weed wacker line to free up some sun-roof drain holes.....

hmm.... do you know that the metallic "tube" that is welded to the drain holes on top...near the sunroof itself.... route toward the rear and drain out of holes that you can see when you lift the engine lid?

Unfortunately, these tubes are connected ( front-to-back) with a rubber sleeve that connects these two metallic runs of tubing....

Maybe you ( or the PO) dislodged the rubber connector sleeve while trying to clean out the tubing...and now the two metal tubes no longe "connect" and allow drain water to enter the car where it shouldn't.

Same deal for the front ( forward-running) tubes.... AFAIK.....

- Wil