2004 Unlimited Pinch Weld Rocker Rust? - JeepForum.com
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Unread 08-28-2013, 03:07 AM   #1
IndridCold89
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1991 XJ Cherokee 
 
Join Date: Sep 2007
Location: Milwaukee, Wisconsin
Posts: 42
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?

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Unread 08-28-2013, 07:03 AM   #2
Zombi
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1999 TJ Wrangler 
 
Join Date: Aug 2008
Location: MA
Posts: 1,460
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.
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