SteveB
Full Access Member
- Joined
- Jun 20, 2019
- Posts
- 312
- Reaction score
- 518
Don't use rivets. Agree get the biggest patch panel you can. Do your best to clean and convert any rust behind the piece you are cutting out.
Dreaded Rust..
- Thread starter Sdp1234
- Start date
Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.
NoReverseYukon
Full Access Member
Like Rocket Man said, find the cause/origin. Does your '04 have 2-piece wheelwell liners ? That is a faulty design and the cause of many dog-legs rusting out.
Tonyrodz
Resident Resident
I'm also have that issue. I've never heard of the 2 piece liner deal before. Is that a known issue? Did they come out with a 1 piece design? Mine is an 03.
NoReverseYukon
Full Access Member
I read about this problem on this forum somewhere. I found a set of 1-piece liners at the junkyard. The photos below are my current 2001 Yukon 2-piece design passenger side and the 2006 Suburban 1-piece.
You will see that the 2-piece design doesn't cover the entire wheelwell and those joints between the plastic liner and metal wheelwell allows anything thrown off by the tire to get behind the liner and work it's magic (AKA rust) on the dog-legs and the rocker panel.
Tonyrodz
Resident Resident
Learn something new every day. Thx.
X2. I just checked, mine are the 2 piece. Seems like another option would be to seal that top edge.
Sdp1234
Full Access Member
Mine is a one piece. Seems like my
issues probably initiate with stuff coming in through this gap
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Sdp1234
Full Access Member
Cut some of the body panel away and cleaning things up. Looks like things inside are pretty good. Plan to cut another couple inches out to make sure there is no rust up higher. My plan is to clean up everything I can see then use a rust encapsulator where ever I can get to. Then primer then piece in the patch panel. When I’m done I’m going to get fluid film in from behind on everything I can get to.
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Sdp1234
Full Access Member
Also going to remove the fender well to look if there are problems higher up that I just don’t see
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Cut some of the body panel away and cleaning things up. Looks like things inside are pretty good. Plan to cut another couple inches out to make sure there is no rust up higher. My plan is to clean up everything I can see then use a rust encapsulator where ever I can get to. Then primer then piece in the patch panel. When I’m done I’m going to get fluid film in from behind on everything I can get to.
Sent from my iPhone using Tapatalk
Nothing like dissecting sheet metal. Nice job.
Sdp1234
Full Access Member
Took off another 2 inches. Looks real clean on the back. But... the actual back of the sheet metal skin still has some rust. Plan to go up 1 more inch and remove the wheel well liners to investigate. I don’t want to take out too much more. Looking for a 2-4 year fix
This is the back side of the skin I removed
Arrow is at the top. Seems like water from above? Or maybe it didn’t drain?
Sent from my iPhone using Tapatalk
This is the back side of the skin I removed
Arrow is at the top. Seems like water from above? Or maybe it didn’t drain?
Sent from my iPhone using Tapatalk
Looks like you are making progress, but i'm not surprised that you haven't found clean metal yet.Took off another 2 inches. Looks real clean on the back. But... the actual back of the sheet metal skin still has some rust. Plan to go up 1 more inch and remove the wheel well liners to investigate. I don’t want to take out too much more. Looking for a 2-4 year fix
This is the back side of the skin I removed
Arrow is at the top. Seems like water from above? Or maybe it didn’t drain?
Sent from my iPhone using Tapatalk
In talking with a buddy who runs a body shop, he said the extra sound proofing material they put into the higher trim packages on Denalis and Escalades is one of the biggest causes of that area rusting on the NNBS vehicles. Might have the same thing going on on your vehicle. Said that the sound proofing material soaks up moisture and holds it and by the time you see rust on the outside, the back side is destroyed.
Hope you find clean metal sooner rather than later.
Sdp1234
Full Access Member
Removed another inch or so Looks like I’m past the bad metal.
Now I’m going to clean up and start the repair
Sent from my iPhone using Tapatalk
Now I’m going to clean up and start the repair
Sent from my iPhone using Tapatalk
Sdp1234
Full Access Member
Sent from my iPhone using Tapatalk
What about that rusted inner rocker piece?
Sdp1234
Full Access Member
The inner rocker panel is not as bad as it looks. I’m grinding out (flapper wheel is taking most of it out) and using an encapsulator. The metal is still very thick, mostly surface rust
Sdp1234
Full Access Member
I think tomorrow is welding day
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Sdp1234
Full Access Member
Welded. Not beautiful but I have some finish work paint and the Denali trim to finish up
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Is that hidden behind the Denali cladding?Welded. Not beautiful but I have some finish work paint and the Denali trim to finish up
Sent from my iPhone using Tapatalk
Welded. Not beautiful but I have some finish work paint and the Denali trim to finish up
Sent from my iPhone using Tapatalk
