Dreaded Rust..

[SteveB]

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.

 

[NoReverseYukon]

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]

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.

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]

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.

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]

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.

View attachment 232329 View attachment 232330 View attachment 232331 View attachment 232332

Learn something new every day. Thx.

 

[Rocket Man]

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]

Mine is a one piece. Seems like my issues probably initiate with stuff coming in through this gap


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[Sdp1234]

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.




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[Sdp1234]

Also going to remove the fender well to look if there are problems higher up that I just don’t see


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[89Suburban]

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.




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Nothing like dissecting sheet metal. Nice job.