99 Malibu - horrible rust near gas cap/door??
acornhead
01-09-2008, 03:13 PM
I have read before that it seems to be a common problem with the Malibu - rust near the gas....cap. Or whatever the little door is called. Mine is bad, and there is actually a small spot where it rusted all the way through and there's a small hole. I definitely don't have the budget to get it fixed right now - is there a short-term "fix" at all?? Someone actually recommended just spraying it with Rustoleum to keep it from spreading/getting worse - would that actually do anything?? Any suggestions would be great, thanks!
stripe
01-09-2008, 09:12 PM
I have read before that it seems to be a common problem with the Malibu - rust near the gas....cap. Or whatever the little door is called. Mine is bad, and there is actually a small spot where it rusted all the way through and there's a small hole. I definitely don't have the budget to get it fixed right now - is there a short-term "fix" at all?? Someone actually recommended just spraying it with Rustoleum to keep it from spreading/getting worse - would that actually do anything?? Any suggestions would be great, thanks!
My 98 has the same rust spot.
Food grade spray works good.If you have a small hole just use epoxy or some such.
In any case spray it every time you change the oil.
Cheers
stripe
My 98 has the same rust spot.
Food grade spray works good.If you have a small hole just use epoxy or some such.
In any case spray it every time you change the oil.
Cheers
stripe
G~Regg
02-05-2008, 12:02 AM
i went to school for auto body and i can walk you throw how u can fix it. and all mats will cost maybe 30$ Email me with the subject at hand and i will let u no Greggore023@aol.com
dirtyhippy
02-18-2008, 01:26 AM
lol yup me too. I saw another one driving aroun with the EXACT rust spot i have it was pretty shocking. Actually now that i think of it that entire panel is bad for rusting. Ive got a spot about 2 inches from the door, all inside the door (but not the door itself) and then right underneath where the panel meets the bumper.
Andy57
02-23-2008, 09:56 PM
ha ha, I have 2 malibus and they rusted in the exact spot. I ground away the rust (careful, there's gas in there !!), I sanded down the area, I body filled it (didn't take much), I primed the body fill, and I painted the area with paint from napa. There is a paint code on the underside of your spare tire cover, napa matched the paint perfectly and its about 20 bucks for a large spray can. Body fill and sandpaper cost me 10 bucks and it looks great.
theboredkiel
10-06-2010, 03:28 AM
The reason this happens is there is a piece of foam directly below the gas cap housing and there is a small gap perfect for collecting salt/sand and never being flushed out because it's somewhat hidden I had the same issue, realized the rust came from the back to the front, and spread once the first speck of paint came off the exterior.. So I just ripped that piece of foam out, and am currently cleaning up the area to prep for bondo. Just figured I'd put in my 2 cents. What a shit design, GM should give all of us a free quarter panel and call it even. And the paint that matches you can just get Dupli-Color BGM0501 which is the one for galaxy silver metallic which is what my car is, I am going to grab some tomorrow after I bondo it tonight, probably sand/prep tomorrow and call it good. I just don't want it to rust more over the winter and be a cut/weld sheet metal job next spring. Bondo is so much easier near fuel.
maxwedge
10-06-2010, 06:51 PM
Good info but 2 1/2 years after the last post, check the dates before posting, thanks.
hotpipes
08-31-2011, 10:55 AM
I could not find an foam in the gas cap door area on my 2002 Malibu I have repired it once but the spot came back I woul realy like to know whats causing this befor I repair it again
hotpipes
hotpipes
Tony Silva
08-31-2011, 11:06 AM
You will need to remove as much of the rust as possible and then use a chemical to neutralize the rust. I would recommend the chemical called 'POR-15'. It will kill the rust. I don't know how it works but it DOES stop the rust.
hotpipes
09-01-2011, 12:16 PM
You will need to remove as much of the rust as possible and then use a chemical to neutralize the rust. I would recommend the chemical called 'POR-15'. It will kill the rust. I don't know how it works but it DOES stop the rust.
Tony I found the rubber padding between the inner and outer skin by grinding more outer body skin off. I can not take all of the rubber out because it is sandwiched between the inner and out skin of the entire wheel well but I got out as much as i could reach and the back side of the outer skin is coated with rust there is an area around the gas fill pipe that is without the inner skin and I can see the rubber sticking out
Do you think it would help to cut off the rubber sticking out and silicone over that seam or just under coat it? I will use the neutralizer before I close it up. Which brings me to another question. The hole is 3" by 6" would you use fiberglass cloth or pop rivet a peace of metal over the hole. The inner skin can and will support the mud if that is the way to go with this repair.
hotpipes
Tony I found the rubber padding between the inner and outer skin by grinding more outer body skin off. I can not take all of the rubber out because it is sandwiched between the inner and out skin of the entire wheel well but I got out as much as i could reach and the back side of the outer skin is coated with rust there is an area around the gas fill pipe that is without the inner skin and I can see the rubber sticking out
Do you think it would help to cut off the rubber sticking out and silicone over that seam or just under coat it? I will use the neutralizer before I close it up. Which brings me to another question. The hole is 3" by 6" would you use fiberglass cloth or pop rivet a peace of metal over the hole. The inner skin can and will support the mud if that is the way to go with this repair.
hotpipes
Tony Silva
09-08-2011, 04:23 PM
I would apply the 'POR-15' first and then pop rivet some sheet metal over the POR-15 and then use body filler to make the repair unnoticeable.
hotpipes
09-17-2011, 07:42 AM
Tony I sanded a larger area and then cut out all the bad metal and removed as much foam as I could reach I used the the neutralizer on any rust I saw. After removing all the foam I could reach It left an opening on the inner skin to the wheel well because the inner skin dose not surround the gas fill tube tightly so I filled the opening with body filler working from in the wheel well and undercoated all around the inner skin wear the foam is sticking out.
I then patched the outer skin with metal and body filler and painted
Two mistakes were. I did not start the filler far enough away from the patch to get a smooth transition. and the other was that I did not paint the whole quarter panel even though I had a good Sherman Williams automotive paint there is a slit difference in the color and it would not show as much if I had Painted the whole panel.
hotpipes
I then patched the outer skin with metal and body filler and painted
Two mistakes were. I did not start the filler far enough away from the patch to get a smooth transition. and the other was that I did not paint the whole quarter panel even though I had a good Sherman Williams automotive paint there is a slit difference in the color and it would not show as much if I had Painted the whole panel.
hotpipes
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