2004 Unlimited Pinch Weld Rocker Rust? - JeepForum.com
LinkBack Thread Tools
post #1 of 2 Old 08-28-2013, 04:07 AM Thread Starter
Registered User
2002 WJ 
Join Date: Sep 2007
Location: Milwaukee
Posts: 45
2004 Unlimited Pinch Weld Rocker Rust?

A year or so ago I noticed I had the tiniest rust spot starting to come through the metal on the lower rocker portion of my passenger side where the pinch weld bumps are. I assumed a chip had got to it and sanded it down and repainted. The rust came back. Did this 2 more times yet the rust kept coming back. To my horror I discovered the rust had started from the other side on the inside of the Jeep by the pinch weld on the floor connecting to the rocker wall. Not sure how to tackle this or how bad it could be. Opening it up made it worse. I tried to POR-15 the area on the exterior after using an angle grinder. It's almost as if there was a thin layer of real metal before reaching the rest of the metal underneath which was nothing but orange. It rusted from the inside out yet the metal still feels solid. Anyone else have this issue or have seen this issue?

Present :
1991 Jeep Cherokee Laredo @ 183,100 : 01/2016
1997 Jeep Wrangler @ 153,200 : 01/2016
IndridCold89 is offline  
Sponsored Links
post #2 of 2 Old 08-28-2013, 08:03 AM
Registered User
1999 TJ Wrangler 
Join Date: Aug 2008
Location: MA
Posts: 1,464
I've seen it from time to time.
The only way to fix rust is to cut it out entirely.
You have to remove 2-3" beyond the visible rust bubble to make sure you got it all.

Call me Z
Originally Posted by mrbates View Post
Zombi's are in fact very unpleasant to be around, they smell, and bite--also, they eat babies.
Zombi is offline  

Quick Reply

Register Now

In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome