• If you currently own, previously owned or want to own an Avalanche, we welcome you to become a member today. Membership is FREE, register now!

Rust on the rear driver's side door

ikehle

Full Member
Joined
Jul 14, 2022
Messages
42
Hey y'all,
My 2002 Avalanche has a now gaping hole in the rear driver's side door floorboard. See pic.

I am considering cleaning out all of the rust, smoothing the edges, then applying Bondo and repainting At least, that was the idea until I looked at it closer. I'm wondering what the consensus is here and whether that might cause more problems than harm. Is it worth taking it to a body shop to let them weld something in place? Thoughts are welcomed.

https://share.icloud.com/photos/0e1TWWCXj5otdxMcjkLN2LzmQ
 
Since it's not a visible area and it doesn't really have any weight bearing, if you don't want to spend a bunch of money, just grind out all rust to bare metal, spray with Rustoleum rust inhibitor primer, spray with some Rustoleum paint to seal (and, if you want, do the Gypsy bodywork with some spray foam sealer, sand to shape, spray paint). Cover back up with trim. Call it a day.
 
Since it's not a visible area and it doesn't really have any weight bearing, if you don't want to spend a bunch of money, just grind out all rust to bare metal, spray with Rustoleum rust inhibitor primer, spray with some Rustoleum paint to seal (and, if you want, do the Gypsy bodywork with some spray foam sealer, sand to shape, spray paint). Cover back up with trim. Call it a day.
Cool, thanks. Yeah I wasn’t too sure if that area might capture water somehow, as if it was expected for water to go through there, since it is hollow. Sounds good.
 
Cool, thanks. Yeah I wasn’t too sure if that area might capture water somehow, as if it was expected for water to go through there, since it is hollow. Sounds good.
Just my .02 and the way I was raised by a Navy Lifer father but I would say do the repair properly and thoroughly inspect the underside of your AV and remove all signs of rust since it's like a cancer affecting your AV. If you plan to keep it for a long time you are going to need to do it right or you will just have ongoing battle with rust.
I would repace all rusted panels with new metal then do what above poster stated about using a good rust preventative primer and maybe even undercoating after painting. It may be a bite to the budget but doing it right could give you an AV that lasts for decades with good preventative maintenance.
 
Cool, thanks. Yeah I wasn’t too sure if that area might capture water somehow, as if it was expected for water to go through there, since it is hollow. Sounds good.

Good point about the possibility of it being a water channel. I don't know that answer, if it you think it is after examining then definitely do not fill with the foam. As Vaeagleav says, you can't go wrong doing it completely "right" with new metal. And, you should definitely examine the surrounding areas for other rust that you can't see.
 
Thank you both. I’m definitely a fan of doing it right. It feels like the first step is at least getting as much rust out of there as possible. I’ll have to see if I can see anything from underneath. I do not yet have welding skills so I’d have to leave that up to a shop.
 
One thing to consider since you have a 2002 AV , it has lower plastic cladding panels and they can hide rust spots.
 
Much cheaper to go South and buy a rust free one, especially if you can't do repairs yourself.
 
Back
Top