R50 Wheel Well Rust

[Densetsu]

Perhaps this is more commonplace in some areas than others... but the rear wheel wells on my '03 Pathfinder are rusting out, and about 1 in 4 Pathfinders I see in Alberta suffer from this.

Mine began on the lip of both rear wheel wells, then slowly crept up and is now prominent on the rear quarter-panel. I tried to sand it down to bare metal and prime/paint it, but it came back within a few months. I think the rust originally began on the top side of the lip, which isn't easily accessible. Can't quite fit an angle grinder in there to get it to bare metal.

In one spot on the lip it's rusted through. On the visible section of the rear quarterpanel it's just surface rust for now, and it's crept up maybe 2" from the lip.

I've spoken to a few shops and lurked around on various boards, and I think my options are:

1. Have the rusted portion of the rear quarterpanel cut out, a new piece of sheet metal welded on, and have it all re-painted. This is the best course of action according to a couple body shops (of course, since it means the most profit for them!)

2. Have the rust sanded/painted again by a pro (not my patchy job lol) so it looks OK, then sell it before the rust comes back.

3. Buy some fender flares, install them (need holes drilled) to hide the rust, and sell the Pathy.

4. Live with it and/or hope I get in an accident so the Pathy gets repaired or written off by the insurance companies.

I do love my Pathy, but this rust issue is terrible and I'm surprised it's not a bigger issue on the board.

Option 3 is likely the least expensive option, but finding flares for the R50 is very difficult, unless any of you guys are aware of a source online.

Has anyone else had this issue? On the board I've seen talk about rust on window trim, nerf bars, above the windshield... but haven't heard much on the board about wheel wells. It's very frustrating, to say the least.
Modified by Densetsu at 1:49 PM 1/18/2010

[Pwnin O'Brien]

I also have large amounts of body rust on my quarter panels under the flares. A couple on months ago I took off all of my flares to assess the rust and it hasn't reached the edges of the flares yet. Here's the way I look at it, even if you repair the rust you wont be able to stop it from coming back again (unless you replace your quarter panels with aluminum panels, which don't exist for the R50). No matter how hard you try, you will never be able to stop the body rust. Once you repair your quarter panels your rear hatch will start to rust. If you take off your rear bumper you will probably be amazed at how must rust there is on the body metal behind the bumper. It's a battle you cannot win so you pretty much just have to wait it out.

[miamiheat3332]

Are there any Technical schools in your area? For example i go to a technical school halfday as part of my highschool schedule.

i talked with the autobody teacher about a week ago and they do the work and labour for free, all you pay for is the paint they have to order.

I asked him how much it would cost to have my front bumper, hood, and i wanted to color match my side mirrors, and also all the black handles on the pathfinder, and he said around 150-200$

so you could check around as they do sometimes even better work than body shops and are dirt cheap.

[Pwnin O'Brien]

Are there any Technical schools in your area? For example i go to a technical school halfday as part of my highschool schedule.

i talked with the autobody teacher about a week ago and they do the work and labour for free, all you pay for is the paint they have to order.

I asked him how much it would cost to have my front bumper, hood, and i wanted to color match my side mirrors, and also all the black handles on the pathfinder, and he said around 150-200$

so you could check around as they do sometimes even better work than body shops and are dirt cheap.

Really? I'm not sure if there are any technical schools that have automotive classes near me. You're not that far from me, I could even drive to Allentown and have it done if it's free labor. I would probably have all of the body metal behind my fender flares sanded down to the bare metal then primed and then have bedliner applied to prevent any further rust.

[miamiheat3332]

I forgot to mention that when i talked to him, he said something about faculty and students only, but im sure i could take it in as my own lol. i will be getting mine done probably around april or so

[Buzzman]

It's probably too late to save your current ride from the rust demons that we get here in Canada (or any where else that road salt is used in the winters), but I have to suggest to you that on your next ride, you oil spray it every year.I've mentioned this in the past (and are probably sick of hearing it), but it works. I've oil sprayed my vehicles for over 20 years, and have never had a rust problem.My Pathy is still rust free. The only thing that showed rust was my window trim, which I replaced last year.There are also many side benefits to oil spraying: The mechanics stay in better shape, nuts and bolts are easier to remove, my doors don't freeze shut in the winters, and the undercarriage is still black and rust free. One downside is that the engine bay looks dirty, but it's just from the overspray attracting dust.

[GRNMACHINE]

I had not heard of oil spraying until a number of years ago when I met some people from the Great White North. They said it was extremely common and they have it done every winter. Is there a link here explaining the full details or can you provide them? Thanks!

[Buzzman]

These are the guys I use now.I was using an independent shop for years, but he closed up. After the first few treatments, you can skip a year now and then. However, I don't go more than two years without having it done.

http://www.antirouille.com/en/auto/index.php

[GRNMACHINE]

Thanks Buzzman, there is more to it than I had assumed. Suprised there is not places here in the States that does it. I know Northern Minnesota has a few places but there are alot more areas that see alot of snow and good ole'rust eating and destroying salted roads.