Premature corrosion?

D

D.K.

Driver side fender of our older car (Subaru Impreza, 1993, FWD) is
corroding with an amazing speed - what was a barely visible spot a year
and a half ago has now become an apple-sized hole with rust spreading as
far as 5 inches from it. Kinda unfrotunate since other things appear
to work OK and the car has only 70 Kmi on it (single owner and regular
maintanence).

One thing I find somewhat strange is that there is no rust whatsover
anywhere else on the car. The fender that has rust all over it is actually
not "native" to the car. The car was 1 year old when there was a minor
accident which resulted in the replacement of the left fender (by dealer,
at the other party's cost). It certainly has no practical implications now, 9
years after, but I am just curious - is it possible that something about the
way the new part was installed ended up causing it's premature corrosion?
If yes, what do I need to know/do in order to avoid this possibility in the
future?

Additionally, I have some practical questions: What is the most cost
efficient way of dealing with it? My intention is to keep this car as
long as it runs OK and costs less in repairs that half the payment
of the new car. I can see few possibilities (but don't have knowledge
to choose between them):
1a) Ignore the rust. As the "epicenter" of the rust if right behind
the wheel and this part of the fender does not seem to cover anything of
importance or serve any significant structural role, one may just hope
that it will be slow enough to reach catastrophic proportions only when
the car starts falling apart.
1b) Same as 1a but with the rationale "wait all the way until it wears
off to the point it simply has to be repaired".
2) Try to find someone who'd do some crude welding job - cut away
everyhting than might be rusted, and stick in place anything that will not
within 5 years or so. (I don't care about easthetics in this case - any
piece of metal and any paint/coat is fine with me as long as it does not
continue to rust; but is t feasible?)
3) Have body shop to install a used fender instead of the current one.
4) Just buy and install a new part.

Just trying to learn and make an educated choice! Thanks for helping out!

DK
 
Hi,

would cut the rusty part out of the fender, paint the wounded iron
and look for a thin aluminium sheet and cover the hole by reviting.
Reveting does not burn or weaken the body. Does not look nice
in other persons opinion, but is fully ok. Just look at the British
Land Rover, the whole body is revitet together.......and you can also pass
the technical test....


Regards from Germany
Tino
 
D.K. said:
Driver side fender of our older car (Subaru Impreza, 1993, FWD) is
corroding with an amazing speed -

They probably replaced the fender with one that is not galvanized. If you
replace it with one that is, it will last.


97T
 
Sounds to me like you got a cheap aftermarket fender on your car.

That's what I was thinking.
If
you have the original insurance info from the wreck where it was
replaced, make the insurance company pay for another one. Many do
have a lifetime guarantee on their crappy aftermarket parts.

Good reason to insist on genuine factory parts.
 
This is why i said there should be paint or anything else between the
Aluminium and
the steel. and........it will by all means last for more then 10 years. In
Bodyrepairs are also
aluminiumrivets used between two ironsheets.....In generall you are right
but in this case
thin aluminium sheet can be nicely formed to cover wholes in fenders. this
is in my opinion
less violation to a fender. Welding is not fine.....and replacing is
........costiv.....

Even Land Rover is reviting aluminium sheets on to steel-frame and Land
Rover body is well
known as a long lasting car and is used all over the world since more than
50 years.....

Regards Tino
 
I agree with most everyone else. Since the fender is then only part that is
rusted I would replace it. Given
the overall condition of the car as compared to this part that was replaced
and the price to have a new OEM
fender prepped,painted and installed it might be to your advantage to go
after the insurance company assuming
you have all the paperwork. Although, I have heard that some insurance
companies are refusing to put new parts on
cars that are over 10 years old so you may have get a used fender from a
salvage yard in either the south or midwest
that is rust free.

On the topic of the current part it sounds like the backside wasn't
prepared/protected from the elements. This is common if the shop wants to
put some more profit in it's pockets. When aftermarket parts come from
factory they have only a light black paint on them. If the car is ever
going to get wet the part needs to be primed and then coated with a
protectant on the back and painted on the outside. It does no good to paint
just one side.

Thanks to everyone who replied! So it seems I was stupid enough 9
years ago to assume that a genuine part is installed (I wouldn't be
able to tell the difference anyway). I don't have time and patience
to chase insurance 9 years after it and it looks like I should be
able to replace the whole thing again for $200. Tolerable.

DK
 

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