Why you should fix the rust on your hatch

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I just got done with a mild repair of this type....Massachusetts '94 after a few years of neglect. I had 2-3 spots of rust starting on the seam.

I removed the window, ground down, primed and painted the rusty spots around the window opening. Looks like I got to it before anything too bad happened. I didn't see any other rust in the area.

I did the whole job myself, installing the window (with new weatherstrip installed) was a bit of a pain. Probably wouldn't be a bad idea to replace the glass if the mirroring tint is getting scraped.

It's my understanding that the window is 'captive' in the weatherstrip, I used 3M window-lok sealer between the window-and-gasket and between the gasket-and-body. Seems ok for a couple months now...

My primary objective is to keep the whole truck from rusting away, it's going well so far :)

Greg C
'94 fzj-80 in Massachusetts
 
Just found a patch on my 1993 80 series today, it goes to the body shop tomorrow for an estimate. Thank God the rear latch quit working or I'd have never found it. The rust is only visable from the inside the car or actually inside the hatch. Hopefully it won't be too bad.
 
Hmmm, good luck. I just had my truck sprayed - every little nook and cranny!

Cheers, Hugh
 
Hey guys thought I would try and revive this thread.. after looking through many upper tail gate rust threads this one seemed similar to mine (although i wish mine was as good as the original picture)...

Some background, Im a CA guy and my car has always been in CA as far as I know (1994 FZJ80). Initially there was a decent sized rust bubble bigger than a quarter that i picked at a bit to check how rotted out it was. I think that it can maybe be thinned down and dont have to cut out all of it what are your thoughts? See image below. I do want to attempt to take care of this myself (here goes nothing!).

i have been able to lift up the window seal a bit (no window sealant is currently there?) without taking it off and dont see signs of rust everywhere which gives me hope i can tackle this job by myself. In doing this I found a lot of dirt pinned against the body and the seal hopefully responsible for water leaking in and causing the rust.

My tentative plan is to pull the window, sand the hell out of any rust real well, cut out really bad parts potentially (think i can get away with just sanding), patch/ fill hole with bondo or something similar, rep-paint everything, apply pinchweld primer to pinchweld (sand first so primer stikcks?), replace old window seal, put window back in, and seal window with polyurethane sealant(thin bead Im told).

I have never done body work myself but i am a surfer and have done lots of surfboard ding repair and feel the process is similar. Also I would say I have good attention to detail, and will work my ass off todo this project well.

I know people strongly advice against using body filler for this job and was wondering why exactly? My thought is that if i completely prep the surfaces really well, patch up the hole nicley, and properly seal the window I would think im fine (maybe i am naïve, very optimistic, or overestimate my skills) !

I also feel like it would be ideal to be clean the inside of the tail gate by maybe running water through it, and apply some sort of rust reformer before I patch up the hole but that does seem tricky to get at...

Any and all suggestions are welcome! thanks

Cheers, Ian

IMG-2398.jpg
 
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That would be the exact same problem with the side cargo windows and why they get so much rust around the bottom. Mine are horrible but due to weather and lack of money I can't do anything except watch the rust grow.
 
That would be the exact same problem with the side cargo windows and why they get so much rust around the bottom. Mine are horrible but due to weather and lack of money I can't do anything except watch the rust grow.
Mine currently appear totally rust free. Is there a way to clean the seal?
 
It seems like most of these eventually develop a rust spot along the lower gasket/pinch weld area and IMHO it's important to stop the rust so it doesn't turn into a hole.

Best method IME (with a windshield) is to completely remove the glass to inspect, remove any rust (flapper wheel), kill any rust in deep pits, then prime and paint. Finish with a new gasket with the old glass.

For a short term/quick fix (if just surface rust, not a hole) you can clean out under the rubber where you see rust, kill the rust with a rust stop product, then prime and paint ie: to slow things down until you can do the complete job. This won't work of course if the rust has already extended beyond what you can see just under the the gasket.

This is a good reminder that we should probably check all the pinch welds on the body that are covered by gaskets or weatherstripping.

FWIW I recently did a quick fix to a spot starting under the hatch glass and then figured I should check the pinch weld around the rear hatch/lift gate body opening, so pulled that large gasket off.

Yup, found a few rust areas already getting started in a dozen places, mostly tiny cracks in the paint at the spot welds, but there were also a few areas that were starting to bubble up on the pinch weld.

Began work on those this week.
 
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If you want to clean under the seal and check for rust at the same time
you could try a plastic upholstery tool to lift the rubber gasket up and away from the sheet metal, then drag a rag using the plastic tool under the gasket. Not sure if it's worth the effort however as an old gasket probably won't lay back down and seal as tightly as the original, so you could end up making it worse unless you have the glass removed, check for rust, then replace the gasket.

Either way, it seems like most of these eventually develop a rust spot along the lower gasket/pinch weld area and IMHO it's important to stop the rust so it doesn't turn into a hole.

Best method IME (with a windshield) is to completely remove the glass to inspect, remove any rust (flapper wheel), kill any rust in deep pits, then prime and paint. Finish with a new gasket with the old glass.

For a short term/quick fix you can clean out under the rubber where you see rust, kill the rust with a rust stop product, then prime and paint ie: to slow things down until you can do the complete job.

This is a good reminder that we should probably check all the pinch welds on the body that are covered by gaskets or weatherstripping.

FWIW I recently did a quick fix to a spot starting under the hatch glass and then figured I should check the pinch weld around the rear hatch/lift gate body opening, so pulled that large gasket off.

Yup, found a few rust areas already getting started in a dozen places, mostly tiny cracks in the paint at the spot welds, but there were also a few areas that were starting to bubble up on the pinch weld.

Began work on those this week.


yeah after i figured out how to take care of my tailgate you have convinced me I need to just pull these windows, buy new seals, and see how rusted the cargo window pinch welds look, sand, repaint, and install with new seal
 
@Mixelplix, the man the myth the legend, haha I have read your thread about 5 times and am very impressed with your results.

Do you think your rust originated from a leaking seal as I suspect for my case?

How has your repair been holding up for you? Did you use a polyurethane sealant once you put the window back in?

Also, I wonder if there is anything one can do to close the gap of the pinch welds.. after all that is the culprit of a lot of these rust issues i believe right?
 
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@Mixelplix

I missed your hatch repair thread when it was originally posted, amazing work.

Most of us would've tossed in the towel then curled up in a fetal position on the floor and cried.
 
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You guys are freaking me out. This is like the thread about mice getting to work on our wiring and interior. Not cool.
 
Just finished cleaning up, sanding, killing rust in pits, priming, and painting the pinch weld and multiple spot welds around the body opening at the rear hatch/lift gate. Not a professional job but should slow it down for at least a few years.

Once the paint cures a bit (I have the hatch/lift gate shut and seam taped off) I'll swipe/spray some 3M Cavity wax over the pinch weld area then install a new gasket/weatherstrip.

Important to note: I do not live in the Rust Belt but still found rust starting
to get a foothold. Best guess is that the pinch weld areas aren't painted all that well at the factory and/or the gaskets trap water and/or the spot welds seem to be rust magnets. About 50% of the spot welds around the rear body opening had a hairline crack in the paint with a slight rust stain showing. Better to stop it before it gets out of control IMHO.

FWIW
 
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Just finished cleaning up, sanding, killing rust in pits, priming, and painting the pinch weld and multiple spot welds around the body opening at the rear hatch/lift gate. Not a professional job but should slow it down for at least a few years.

Once the paint cures a bit (I have the hatch/lift gate shut and seam taped off) I'll swipe/spray some 3M Cavity wax over the pinch weld area then install a new gasket/weatherstrip.

Important to note: I do not live in the Rust Belt but still found rust starting
to get a foothold. Best guess is that the pinch weld areas aren't painted all that well at the factory and/or the gaskets trap water and/or the spot welds seem to be rust magnets. About 50% of the spot welds around the rear body opening had a hairline crack in the paint with a slight rust stain showing. Better to stop it before it gets out of control IMHO.

FWIW

Nice got any pics? Im curious how it turned out and how bad your rust was
 
Rust wasn't terrible but maybe in 10 years it would have been. Repairs came out good, probably put the paint on a bit too thick but it's 95% under the gasket so the whole point was to stop the rust from getting worse. Photos to follow
 
Mine currently appear totally rust free. Is there a way to clean the seal?
The issue is that the seal 'traps' water and that's what causes the metal seam the seal hides to rust out. I hope to pull my cargo windows and try to deal with the damage. I think the seals are still available new.
 
Just finished cleaning up, sanding, killing rust in pits, priming, and painting the pinch weld and multiple spot welds around the body opening at the rear hatch/lift gate. Not a professional job but should slow it down for at least a few years.

Once the paint cures a bit (I have the hatch/lift gate shut and seam taped off) I'll swipe/spray some 3M Cavity wax over the pinch weld area then install a new gasket/weatherstrip.
Out of interest, what rust treatment and primer and paint products did you use? I've not seen 3m cavity wax before so will check that out. I agree that the spot welds can be annoying as they are always a weak point in my view for corrosion to start.

Craig.
 
I'm not a body repair expert but FWIW I've used a few different brands of rust killers, all have Phosphoric acid, different countries will have different products/brands available. IMO they all work about the same, remove surface rust, apply the product for any rust remaining especially pittting that you can't remove, let it sit ?? minutes (depending on the product), then rinse off. Some require a repeat application. For a quick job like this about any aerosol primer then aerosal paint designed for autos/metal. Best would be an epoxy primer and a catalyzed paint (2K or two part) but then you're getting into more money.

The 3M cavity wax is just that, a light tan waxy liquid that goes on wet then the solvent flashes off leaving a slightly tacky wax. It can be used to help rustproof an entire vehicle and is used by body shops generally after a body panel is removed to bring that area back to OEM specs regarding rustproofing.

I use it for example while working on a door after cleaning it out, or a quarter panel, or tailgate cavity. For difficult to get area you can spray it in any small hole sometimes by removing a hole cover/plate, a bolt, or even a screw.

There is also a Wand kit of different length tubes/nozzles that can be purchased separately, comes with a 3 foot and 2 foot wand with tips that spray in multiple directions and a 8 inch nozzle. The longer wands help spray the wax deep into a body panel/cavity. The shorty can be used to flood seems and joints but you don't want to block any drain holes of course.

Some examples: I removed one screw for the latch thingy on the lower side of the upper hatch, then stuck the three foot long wand into that threaded hole and sprayed the product as I pulled the wand out. Did both sides and repeat. Idea was to coat the lower inside of the hatch where rust often occurs. The wax is thin enough where it shouldn't interfer with the lock linkage.

The upper aspect could be reached via where the washer nozzle hose or the wiring goes into the hatch. Or you could remove the lower plastic panel on the hatch, then open up the access panels and snake the wands in that way.

Same for the Tailgate; either remove a bolt for the latch mechanism and snake the wand in that way, or maybe better, remove the carpet then the access panels and spray directly.

For the rocker panels many ways to get into there; removing a rubber hole plug on the inner aspect of the rocker panel from either end would be easiest. Don't spray too much and plug the drain slits.

Hood and fenders, plenty of access.

Quarter panels: you could remove the rubber drain plug (which might tear), and spray in that way, or better, remove the panels in the cargo area. That allows you to check the condition of the bottom of the cavity to see if rust has already started. One problem there is to be careful how much you spray as you don't want the mist to come back out onto your carpet. Only the bottom and rear aspect of the cavity and the section that runs forward around the wheel hump and down to meet up with the rocker panel need to be coated IMO.

But for the current pinch weld project after the paint is cured I'll spray some directly on the pinch weld and then I'll probably swipe it with a cloth saturated in the wax to spread it around evenly Once the wax/solvent dries I'll install a new gasket.




 
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@Mixelplix, the man the myth the legend, haha I have read your thread about 5 times and am very impressed with your results.

Do you think your rust originated from a leaking seal as I suspect for my case?

How has your repair been holding up for you? Did you use a polyurethane sealant once you put the window back in?

Also, I wonder if there is anything one can do to close the gap of the pinch welds.. after all that is the culprit of a lot of these rust issues i believe right?


Thanks! I tend to jump into things head first.

Yes, I believe there's a combination of water being trapped in the window seal, and the natural tendency for our trucks to collect grit and grime at the rear hatch area when driving (due to aerodynamics).

My hatch is still holding up well (knock on wood) a few years later.

I wouldn't close up the pinch weld with caulk or anything. When I reinstalled my back glass I slathered the gasket with dielectric grease to help with lubrication. If I were being extra cautious I would do that every decade or so to help keep water out.
 
FWIW the 3M Cavity wax isn't caulk if that's what it sounded like, it's a very thin liquid, solvent and wax, the solvent flashes off leaving behind a very thin wax (not thick like candle wax). It's what body shop's use as part of a repair to bring the vehicle back to OEM specs:

 
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