GM Truck Club
Founded in 2004 ~ We're the #1 Chevy Truck & SUV Forum.
Silverado & Sierra | Tahoe & Yukon | Suburban & Yukon XL | SUV & CROSSOVER
Results 1 to 5 of 5
  1. #1

    Default Best way to patch or fiberglass rust

    I was looking at my rocker panels and there is a rust spot that is about to make a hole but whhat is the best way to fix that before it happens

  2. #2


    moved to maintenance & upkeep sub forum. changed title to make subject more clear.

    1995 Silverado 4x4
    6" BDS Suspension Lift-3" Body Lift-Add A Leaf in rear -Trailmaster SSV Shocks-Duel Steering Stabilizer Kit -AirAid Cold air intake-
    4.56 Gears with Detroit Auburn Locker-Pro-Comp Traction Bars with duel shocks-Aluminum Skid Plate Kit-38.5" x 16.5" Mickey Thompson Baja Claws-Constant Dropping fuel gauge

    2005 Yukon XL Jet Power Programmer, Bilstein Shocks, Bilstein rear springs, Helwig Anti-sway bars, EGR Window Visors, EGR Hood Shield, Denali Headlights, Headlight harness upgrade, GE NightHawk Bulbs, White Night Rear lighting system, Russell Braided SS brake lines, PowerStop Brake pads, PowerStop cross drilled and Slotted Rotors,
    2002 Silverado ext cab 2wd (Sold)
    2003 Yukon XL (Totaled)

  3. #3


    How big are this rust areas? Small like a dime? Quarter? Larger?

    There are a couple of ways to go about this. Everything from sanding and bondo to just covering it over with Diamond plate (I've got a buddy who that's all he would do...)

    10 Chevy Traverse LT AWD
    02 Chevy Trailblazer LS (110K+ miles - loaded except for 4WD - WRECKED!)
    99 Chevy Cavalier LS (105K+ miles - commuter car)
    78 Chevy Suburban Silverado (454, 3/4 ton)
    62 GMC 3/4 ton Pickup (350 police interceptor)

    Remember: Search Before Posting | Fill out Your Profile & Signature
    * I've been saying for years that I was going to change my username, and I finally did.

  4. #4

    Join Date
    Sep 2010
    everett, massachusetts


    you will need a cut off wheel tool . you cut out all the rusted metal . then get some galvanized sheet metal and make a patch to fit. using a rivet tool/drill install rivets to hold in place. then use fiberglass reinforced bondo to cover the area. grind down so you get is level / kinda smooth. then use regular bondo to get the surface very smooth no pin holes. then prime/paint.

    with rust coming thru the rocker you will have a good amount of metal to be replaced probably a 4 in X 12 inch section ...

  5. #5
    Jr. Engineer poncho62's Avatar
    Join Date
    Sep 2013
    Hanover, Ont, Canada


    Your best bet is to cut out the rusted material, cut a patch of sheet metal the same size and weld it in. You then grind down the welds and finish with as little bondo as possible. A good body man can do it without using any bondo. Then epoxy prime and paint.

    A quick fix is to grind the spot a bit, dent it in a little and fill it with short strand fiberglass, sand, prime and paint....

    Depends on how long you want it to last

    1997 GMC

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts