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Love my G but why do they all rust in rocker and other panels.
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Posted 11/8/2015 10:03 AM
JCH4
Regular


Date registered: Jun 2010
Location: Charleston, SC
Vehicle(s): 2003 G500, LR 1972 IIA, LR 1962 IIA, Husqvarna 350
Posts: 74
50
Love my G but why do they all rust in rocker and other panels.

Love my G but why do they all rust in rocker and other panels. Our 2003 MY G500 needs rocker panel and bottom A and B pillar replaced already. I am having it done but the G is only 12 years old. In addition, I have routinely kept it up and sprayed with Waxoyl one a year. Tips or advice appreciated.
#230230
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Posted 11/8/2015 10:22 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE, 2015 Audi Q7 3.0 TDI
Posts: 9770
5000
RE: Love my G but why do they all rust in rocker and other panels.

My 2000 G500 has had no rust problems to date. Of course this probably due to the fact that spent its first two years in Dallas and the last 13 yrs in Atlanta - neither location having much, if any, exposure to salt.

Your by the sea location probably exacerbates the rust situation. Has the truck always been located there, or did come from an area with even more salt?
#230231 - in reply to #230230
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Posted 11/9/2015 6:30 AM
thebigblue
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Date registered: Jan 2012
Location: Denmark
Vehicle(s): G400 CDi 2005 Limited Edition #045/250
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RE: Love my G but why do they all rust in rocker and other panels.

Seems odd to have rust in a not that old truck, mine has lived on salted and wet roads for 10 years now, - no rust apart from the occasional spot from a stone-chip....
#230241 - in reply to #230230
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Posted 11/10/2015 10:38 AM
JCH4
Regular


Date registered: Jun 2010
Location: Charleston, SC
Vehicle(s): 2003 G500, LR 1972 IIA, LR 1962 IIA, Husqvarna 350
Posts: 74
50
RE: Love my G but why do they all rust in rocker and other panels.

I will try and take photos of the rust before it is repaired if I can get by the body shop in time. I purchased the car from an AUDI dealer back in 2008 located outside Chicago, IL. I do not recall noting any significant rust at that time. The first thing I did was clean underneath and spray the cavities and frames with WaxOxyl to, hopefully, prevent rust. I have owned a number of Land Rover Series trucks that is why I had the WaxOxyl compressor kit. In addition, when I purchased the G500 the first thing I did was remove the factory running boards and spare tire cover.
#230266 - in reply to #230241
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Posted 11/10/2015 12:40 PM
emlmcb
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Date registered: Dec 2006
Location: Buenos Aires, Argentina
Vehicle(s): 1986 LWB 300GD / 1998 E320 / 1996 LWB G300TD
Posts: 119
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RE: Love my G but why do they all rust in rocker and other panels.

I agree with most of the former answers. My 1996 G300DT shows no sign of rust even when the former owner (a friend) an myself really use it off road.
My former ride, an 86 300GD did rust over and over around the tailights as all the other 460´s here do.
I think the plastic rear fenderwell in the 463 really solved the problem.
My only guess is that your previous owner got yours into salt wáter or something like that and that it got trapped into the undercarriage of yours.
#230272 - in reply to #230230
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Posted 11/10/2015 12:58 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE, 2015 Audi Q7 3.0 TDI
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RE: Love my G but why do they all rust in rocker and other panels.

JCH4 - 11/10/2015 10:38 AM

I will try and take photos of the rust before it is repaired if I can get by the body shop in time. I purchased the car from an AUDI dealer back in 2008 located outside Chicago, IL.


That probably explains the original source of the problem.
#230273 - in reply to #230266
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Posted 11/10/2015 1:26 PM
TD1
Member




Date registered: Apr 2015
Location: Brooklyn, NY
Vehicle(s): 2004 G500 // 97 Disco
Posts: 22

Re: Love my G but why do they all rust in rocker and other panels.

My Northeast 04 G500 has rust, but yours seem a little more severe than mine.

I have some body rust issues like the hinges (and bubbling paint on the mirror stands), but my most significant issues are the rear cargo door bottom seam below the spare and rear passenger side panel by the fuel door. As for the undercarriage, my frame is fine and in a lot of spots looks factory new, but the worst corrosion occurs around the area of the rear bumper which I guess is more at risk from salt water spray from the rear wheels (worst case, this is a good excuse for a rear steel bumper and new hardware I guess).

#230274 - in reply to #230266
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Posted 11/15/2015 10:41 AM
JCH4
Regular


Date registered: Jun 2010
Location: Charleston, SC
Vehicle(s): 2003 G500, LR 1972 IIA, LR 1962 IIA, Husqvarna 350
Posts: 74
50
RE: Love my G but why do they all rust in rocker and other panels.

Photos of rust. It appears they are rusting from outside in and not from inside out which is opposite of what I thought would happen. The body shop wants $4k plus to replace the rocker panel, front pillar, and middle pillar. Seems expensive but necessary. Anyone have any thoughts on both the rust and fix?



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#230338 - in reply to #230230
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Posted 11/15/2015 3:15 PM
03-Gwagen
Elite Veteran


Date registered: Apr 2006
Location: Western Pennsylvania
Vehicle(s): CLK63 Black Series, 2018 G63, 2016 GLE300d
Posts: 884
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RE: Love my G but why do they all rust in rocker and other panels.

I saw this starting on my 03.

There is a weld there and the rubber molding does not fit tight there. IMO, water and salt gets in those spots.

On my newer G's, I use flowable windshield silicone to seal those spots.



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#230340 - in reply to #230338
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Posted 11/15/2015 4:03 PM
oskar
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Date registered: Sep 2006
Location: Lyons, CO
Vehicle(s): 1981 280GE, 2002 G500, 280SE 4.5, Audi A4 1.8T
Posts: 698
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RE: Love my G but why do they all rust in rocker and other panels.

Those rubber moldings have metal inside which also badly rusts, then the moldings twist and capture water and mud.
if not taken care of in time .... result is rusting thru

Oskar
#230341 - in reply to #230340
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Posted 11/16/2015 9:58 AM
emlmcb
Veteran


Date registered: Dec 2006
Location: Buenos Aires, Argentina
Vehicle(s): 1986 LWB 300GD / 1998 E320 / 1996 LWB G300TD
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RE: Love my G but why do they all rust in rocker and other panels.

Oskar:
You refer to rubber mouldings with metal inside that rust. my 86 300GD had those but my 96 G300TD has plastic mouldings with no metal inside.
The original question was about a 03 G500, so I would asume that it should have the plastic ones.
#230352 - in reply to #230230
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Posted 11/16/2015 10:22 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE, 2015 Audi Q7 3.0 TDI
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RE: Love my G but why do they all rust in rocker and other panels.

emlmcb - 11/16/2015 9:58 AM

Oskar:
You refer to rubber mouldings with metal inside that rust. my 86 300GD had those but my 96 G300TD has plastic mouldings with no metal inside.
The original question was about a 03 G500, so I would asume that it should have the plastic ones.


The moulding along the bottom edge under the doors does contain metal to restrain the screws holding it in place.
#230353 - in reply to #230352
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Posted 5/5/2019 1:02 AM
spots350sl
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Date registered: Mar 2007
Location: Chicago, Illinois
Vehicle(s): 2003 G500, 1972 350SL
Posts: 217
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RE: Love my G but why do they all rust in rocker and other panels.

I've noticed that my rocker moldings are also starting to rust/warp and I want to replace them/treat the metal underneath before it spreads.

How do I remove the rocker moldings? I've run a search, but couldn't find an answer.

Thanks!
#240652 - in reply to #230353
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Posted 5/5/2019 6:38 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE, 2015 Audi Q7 3.0 TDI
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RE: Love my G but why do they all rust in rocker and other panels.

spots350sl - 5/5/2019 1:02 AM

I've noticed that my rocker moldings are also starting to rust/warp and I want to replace them/treat the metal underneath before it spreads.

How do I remove the rocker moldings? I've run a search, but couldn't find an answer.

Thanks!


There is a rubber flap running lengthwise in the middle. The attachment screws are underneath it.
#240653 - in reply to #240652
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Posted 5/5/2019 12:39 PM
spots350sl
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Date registered: Mar 2007
Location: Chicago, Illinois
Vehicle(s): 2003 G500, 1972 350SL
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RE: Love my G but why do they all rust in rocker and other panels.

Wonderful, thanks Dutch! I had a feeling, but was afraid to just tug at the strip without first confirming.
#240654 - in reply to #240653
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Posted 5/7/2019 10:46 PM
AGuess
Elite Veteran


Date registered: Apr 2006
Location: Holly Springs NC
Vehicle(s): 93 500GE, 93 500GE, 2002 G500
Posts: 647
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Re: Love my G but why do they all rust in rocker and other panels.

One of my 93 500GE started to develop rust at the door pillar, under the body side molding.

I found that under the car, below the pillar is a round rubber drain tube. This was clogged up, resulting in water staying inside the pillar and the rocker panel. Check to see if your G has these drain tubes and open them up. I did not know they were there or I would have done this as routine maintenance.

Hope this helps.

AGuess
#240665 - in reply to #230230
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Posted 5/8/2019 10:32 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE, 2015 Audi Q7 3.0 TDI
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Re: Love my G but why do they all rust in rocker and other panels.

AGuess - 5/7/2019 10:46 PM

One of my 93 500GE started to develop rust at the door pillar, under the body side molding.

I found that under the car, below the pillar is a round rubber drain tube. This was clogged up, resulting in water staying inside the pillar and the rocker panel. Check to see if your G has these drain tubes and open them up. I did not know they were there or I would have done this as routine maintenance.

Hope this helps.

AGuess


A great tip. Thanks Alex!
#240666 - in reply to #240665
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Posted 5/28/2019 3:08 AM
TPONZ
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Date registered: May 2018
Location: Taupo, New Zealand
Vehicle(s): 93 W463 G300 SWB, BMW 535D MS & Porsche 944S2
Posts: 24

RE: Love my G but why do they all rust in rocker and other panels.

DUTCH - 5/5/2019 10:38 PM

spots350sl - 5/5/2019 1:02 AM

I've noticed that my rocker moldings are also starting to rust/warp and I want to replace them/treat the metal underneath before it spreads.

How do I remove the rocker moldings? I've run a search, but couldn't find an answer.

Thanks!


There is a rubber flap running lengthwise in the middle. The attachment screws are underneath it.


I had the same problem where the steel fittings rusted, expand and distort the mouldings so I had to buy new ones
which i thought were very expensive. These are sometimes difficult to remove as the screws rust also to the point
where they have to be drilled out and then the bits inside retrieved from the drain holes beneath the sills.
For this reason I used stainless screws to attach the new mouldings. Something to watch for the mouldings
are different for left and right, they will fit but not properly unless you have them on the correct side.
#240721 - in reply to #240653
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Posted 5/31/2019 1:25 AM
JamesG
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Date registered: May 2006
Location: Conifer, Colorado
Vehicle(s): 2011 G550, 2000 L.C.,1997 L.C.1987 FJ60
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Re: Love my G but why do they all rust in rocker and other panels.

I am disappointed when I see the occasional story about rust on our trucks. Disappointed because I think about videos from the factory and the processes I see with coatings on the assembly line. I don't understand it. Anecdotally both my 2002 and my 2011 are rust free with just a few small exceptions. These are due to stones hitting the paint and exposing bare metal. I have heard of one problem and that is the top of the rear spring perches? Does Perches sound right? Anyway I try to keep those clean. A lot of folks in the areas around Denver coat their frames with Fluid-film but that won't help the body. I gotta say the Mag Chloride CDOT uses is horrible and is hard on wiring as well. That includes power lines and Transformers too, Horrible! I would be fine with just applying this garbage on our hi ways at intersections only; where you need some sort of aide to accelerate from a stop.
#240733 - in reply to #230230
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Posted 6/3/2019 8:06 AM
WEBIII
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Date registered: Oct 2010
Location: Fairfield, CT
Vehicle(s): 461/463
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Re: Love my G but why do they all rust in rocker and other panels.

JamesG - 5/31/2019 12:25 AM

I am disappointed when I see the occasional story about rust on our trucks. Disappointed because I think about videos from the factory and the processes I see with coatings on the assembly line. I don't understand it. Anecdotally both my 2002 and my 2011 are rust free with just a few small exceptions. These are due to stones hitting the paint and exposing bare metal. I have heard of one problem and that is the top of the rear spring perches? Does Perches sound right? Anyway I try to keep those clean. A lot of folks in the areas around Denver coat their frames with Fluid-film but that won't help the body. I gotta say the Mag Chloride CDOT uses is horrible and is hard on wiring as well. That includes power lines and Transformers too, Horrible! I would be fine with just applying this garbage on our hi ways at intersections only; where you need some sort of aide to accelerate from a stop.

Particularly at the rear upper shock mounts. The way the 2 layers of steel create a pocket for salt, mud, etc to accrue is a design flaw IMO. It’s difficult to washout that area.
#240745 - in reply to #240733
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