rust through! Is this spot common?

[Volkovich]

I am planning on getting my 911SC repainted next year because the previous owner really botched up the paint job. They only painted over the existing paint and it is flaking off in spots. I plain on having it stripped down to bare metal and done right this time.

In the mean time, to make sure that there aren't any major rust spots I was applying POR-15 to any trouble areas. I was really bummed when I found a complete rust through area. It was underneath the rubber door guard on the bottom of driver's side near the door handle side. I found it by removing the rubber guard and the spot is about 2"x2" all the way through the metal.

What should I do to keep it from growing and how do I fix it? Can it wait until my restoration project? Finally, if this is a common spot what other spots should I go look into?

[Huey581]

I just had the same area repaired on my 86' cab. I purchased
a repro door sill from Stoddard for $ 65.00 dollars. My body man used this as a doner piece and cut out what he needed to weld into the sill to make the repair. It would have been difficult to fabricate the repair piece. Came out fantastic!

[masraum]

This has come up before. Apparently it is a weak spot for the galvanized cars. Up underneath that section (if I am correct in my assessment of where you say it is) is where two areas of metal come together and dirt is caught in that area since it is under the care With that dirt sitting there holding moisture over a long enough period of time you see the results. From your description it could be worse. See if THIS is the same place that you are speakign of.

[HawgRyder]

My '69 has a small hole on the drivers side...but only on the horizontal surface.
I thought that the PO had drilled a hole to get to the jack point for some reason and not painted it after drilling.
The hole is nearly round and about 1 1/2" in diameter.
Since this thread indicates that it should not be there...I will fill it in.
Bob

[Volkovich]

Originally posted by masraum
This has come up before. Apparently it is a weak spot for the galvanized cars. Up underneath that section (if I am correct in my assessment of where you say it is) is where two areas of metal come together and dirt is caught in that area since it is under the care With that dirt sitting there holding moisture over a long enough period of time you see the results. From your description it could be worse. See if THIS is the same place that you are speakign of.

Yep. That is it. Luckily mine doesn't look that bad. I will read through the original post to find out what to do about it. I have coated it with POR metal prep and plan on putting some POR paint on there until I figure out what to do about a permanent repair.

Thanks.

[Erakad]

Had same problem on both sides. I cut out the rust, left a hole about 1 1/2 - 2 inches wide. Applied the rust remover. Went to autozone, bought this stickon aluminum grid that goes with bondo, used that to support the bondo, sanded it all down nice and smooth, applied primer, black paint, and reapplied the rubber sill. This time I made sure that water couldn't seep underneath. It appears pretty dry now, although the fix isn't beautiful, the wonders of the rubber sill mask my handiwork.