The only rust on my 80...uggh...any thoughts? (1 Viewer)

[Congo Cruiser]

1995 FZJ80. 170,000 miles.

Just discovered this small bit of rust on the front driver’s wheel well under the battery box and just behind the headlight...

It’s the only rust on the vehicle, so I guess should count myself lucky!

Anything I can do to keep it from spreading, apart from keeping it dry of course? Not keen to disassemble and properly repair it at this point. Hoping there is a quick fix that can keep it in check until properly addressed next summer.

I think some debris got caught in there and allowed water to pool. I’ve cleaned it all out and it’s draining now.

It’s a tough spot to reach - the lip under the battery box.

Thanks for any tips or suggestions

 

[cowboyjack]

The Rust Store makes a nice gel rust remover. Spread some on as best you can and call it good until Spring?

 

[nigelsiam]

Can you tell if the rust has eaten through the metal? Either way you are going to have to take the time to get in there and either remove that surface rust and apply a rust inhibitor/spray sealer primer. If it's rusted through you HAVE to fix it unless you want a much bigger problem on your hands. How do I know? I live in Minnesota!

 

[Malleus]

Ospho, if you can get it where you are.
Ospho Rust Treatment - Since 1947

 

[Congo Cruiser]

The Rust Store makes a nice gel rust remover. Spread some on as best you can and call it good until Spring?

Thanks. Looking into that now.

 

[Congo Cruiser]

Can you tell if the rust has eaten through the metal? Either way you are going to have to take the time to get in there and either remove that surface rust and apply a rust inhibitor/spray sealer primer. If it's rusted through you HAVE to fix it unless you want a much bigger problem on your hands. How do I know? I live in Minnesota!

Thankfully it’s not rusted through, but it looks like it’s on it’s way to that. I’ll definitely have to address it in the Spring.

I’ll work on disassembling, removing the surface rust and then trying one of these rust inhibitors.

Minnesota has great camping, but those winners take a toll. Thanks for the reply.

 

[Congo Cruiser]

Ospho, if you can get it where you are.
Ospho Rust Treatment - Since 1947

Thanks @Malleus. I’ll look into that as well.

 

[Tedward]

In the meantime shoot some oil or grease on it.

 

[Fj81]

You can completely remove that inner fender and deal with it or replace it if it gets bad enough. It is just bolted on.

Oopsie

• Fj81
• Jan 2, 2017
• 1

Damage on front of FJ80, replaced inner fender.

So just do what you can to clean it and treat it for now and dont worry too much about it.

 

[Congo Cruiser]

Going to give this a try later in the week...

 

[Congo Cruiser]

You can completely remove that inner fender and deal with it or replace it if it gets bad enough. It is just bolted on.

Oopsie

• Fj81
• Jan 2, 2017
• 1

Damage on front of FJ80, replaced inner fender.

So just do what you can to clean it and treat it for now and dont worry too much about it.

Thanks. I’ll go down that path this Spring. Appreciate the reply.

 

[Tedward]

The gel burns paint off as well.
There are other brands, it's just acid. Naval Jelly and so on.
Apply it with a brush. Rinse and repeat til it's shiny if your going to paint it.
Rinse it off really well the last time. It tends to stick a bit in the little tiny holes it dissolves.

 

[cowboyjack]

With a little common sense, I haven't found the Rust Store's Gel to remove paint, just rust. That's why I use it for applications like this. Same for Evaporust, but it won't stick to vertical-ish surfaces.

Any of the "rust converter" phosphoric acid products I've used -- like Ospho or POR 15's Metal Prep, will definitely eat paint.

Highly recommend a converter product AFTER you do the rust removal, including physical scraping, wire brushing, sanding, chipping, etc. AND a rust removal product. Then the converter, then prime and paint.

YMMV

 

[retrofive]

Sorry for your loss, you will have to burn it to the ground now. She was a beaut Clark.


J/K
I honestly would try the naval jelly.

 

[Congo Cruiser]

Really liked @retrofive’s comment!

So frustrating. Dug into this today - literally dug.

It was much worse than surface rust. It had eaten clear through the driver’s side front fender. It was still moist, damn it!

Here are some photos (notice in the second photo the size of the hole...and how it grew after removing rotten metal by the time I took the third photo!)...

I’ve removed what I could with a screwdriver and pliers and bent the good metal back on itself in the wheel well. I’ve tried to protect those two lines running above the area (transmission cooler?).

I’m replacing the 23 year old original factory radiator this summer with a new OEM radiator as PM. I’ll have much better access then. I’ll probably see about getting a professional to look at it, as I sure don’t know what I’m doing.

I do think I got all the rusted crap out though. I’m going to cover what’s left with the naval jelly I got and call it good until summer.

Any tips or corrections to what I’ve done are most welcome!

 

[Congo Cruiser]

It’s a real shame, as the truck is in great shape given all the places it’s been...

 

[Congo Cruiser]

I’m glad I caught it though. It was just hiding under the battery box. I’ll be carefully looking for other hidden rust in the weeks ahead. Thanks everyone.

 

[Dave 2000]

A battery boiling over in the past perhaps? Takes off the paint and moisture does the rest. The tin worm is eating the rear of my sills, pisses me off, I will have to sort it next year or it will not make the test.

Regards

Dave

 

[cowboyjack]

Had some rust that ate through on my rear wheel well. After removing and treating rust and then painting with POR 15, used fiberglass resin, cloth, 3M metal screen and bondo to cobble up a repair. Then painted again. Is it pretty? Not so much... will it rust again in my life time? Don’t think so. Watched several videos on you tube to get ideas. After all... it’s just rust!

 

[Congo Cruiser]

Thanks @Dave 2000 and @cowboyjack.

I’ve never had a battery issue. I think this was caused by debris caught in the area that caused water to pool.

I’ve pretty much removed all the rotten metal, have done a couple applications of naval jelly and will brush on some rust inhibitor this afternoon.

This summer while replacing the radiator I’ll come up with something like @cowboyjack’s repair.

It’s completely hidden under the battery box in the wheel well. Doesn’t need to look pretty. Just need to keep any remaining rust from spreading.

Thanks guys.