Can repair rust holes in the body of my car, with gap filling foam?

Question

I've got big (some 5 inches across, by 2 inches) rust holes in the bottom of my rocker pannels on my little chevy sprint, they're right into the interior!
Is it okay to use rust converter, then patch the holes with that expanding foam from the inside, then spray with rubber sealer and rust paint on the exterior?
I'm afraid it'll cost tonnes to get the pannels replaced...I need some advice please!

Answer 1

If you want to fix a hole this big, it will need a metal skin patch, which can be welded. You need someone who knows how to do this. The problem with a hole this big is that the hole is rotten around the edges and when you work on it you will need to cut it to the good metal. You will not have to replace the panels unless this problem is all over the panel. This is only if you want it fixed right. If you are looking for a quick fix, you might do like you were talking about.

Answer 2

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RE:
Can repair rust holes in the body of my car, with gap filling foam?
I've got big (some 5 inches across, by 2 inches) rust holes in the bottom of my rocker pannels on my little chevy sprint, they're right into the interior!
Is it okay to use rust converter, then patch the holes with that expanding foam from the inside, then spray with rubber sealer and ...

Answer 3

Its a real back woods way to do it. That will work, but I suggest using body filler on the outside, something like bondo. The body filler will make it look more like metal, because I dont think you'll be able to get that thing inspected with rust holes. You could use fiberglass if you wanted to go a notch above the expanding foam and bondo trick. I've seen people use duct tape and just spray paint over it to pass inspection.

Answer 4

Hmm,,,
I've never heard of such an unusual solution to this problem. I don't see why it wouldn't work...
A better (and neater looking) solution might be to treat and fill the holes as you planned, then cover the area with fibreglass patch. Then you can sand it down, spray-can it and it would look pretty good! Plus the "glass patch" is waterproof (unlike Bondo) and wouldn't rust out again.
The kit to do this includes instructions. Hell, I did it on my old Datsun for the first time this Fall, and it looks fine!

Here's the kit:
http://www.shopatmidway.com/pc-737-3-fiberglass-repair-kit.aspx

Answer 5

What I would do is use the spray foam use a sand block sand it down smooth then use like a spray on bed liner from auto zone or orielies and paint the bottom half with it so it looks even I've done it to my 1988 s10 blazer and you can't tell the difference make sure you don't go to think as then it will feel rubbery with to much of the spray liner.

Answer 6

I did this myself, it works. I removed the rust, filled the gaps with foam and then used plastic bondo over the foam. It turned out great.

Answer 7

it's funny that i see this question posted today because earlier i i had done this very same repair on a old car that had to pass a safety to be used as a winter beater for a customer of ours it's cheap and it will get you down the road so why not!

Answer 8

If your rocker panels are rusted that bad then you need to replace them.These are part of the frame of your car

Answer 9

Orielies

Answer 10

it won't last....patch panels cut to the size you need and welded into the spot then grinded down flush, body filled with rage gold body filler, primed, painted , and then clear coated...rage can be bought at your local auto paint supply store...thats if you want it to last