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Old 03-02-2011, 05:13 PM   #1
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Default 2002 Bonneville: Rust under gas filler door

A poll: Does anyone own a 2002 Bonneville that is rusting through beneath the gas filler door?
Mine is doing it and I've seen at least one other doing the same thing.
The rest of the body is primo.
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Old 03-02-2011, 05:16 PM   #2
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Just finished ripping sawgunners 2000 and throwing it on the scrap heap for the same problem. That comes from spilling ethanol.
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Old 03-02-2011, 05:41 PM   #3
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Same happened on my 2001 SSEi. Paid $600 to have the cancer removed, new metal put in, prepped and painted. The guy that did it for me told me there is a section under there where inner and outer panels come together, and there is a sealer between the two that was trapping water and caused the rust. Design flaw, which is why this affects so many Bonnevilles of that generation.

Get it fixed before it gets worse.
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Old 03-04-2011, 11:10 AM   #4
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Quote:
Originally Posted by 2kg4u View Post
Same happened on my 2001 SSEi. Paid $600 to have the cancer removed, new metal put in, prepped and painted. The guy that did it for me told me there is a section under there where inner and outer panels come together, and there is a sealer between the two that was trapping water and caused the rust. Design flaw, which is why this affects so many Bonnevilles of that generation.

Get it fixed before it gets worse.
When did you have it done? I have a friend who runs the best body shop in my area. He said he could do the same thing you had done but no telling how long it would hold up.
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Old 03-04-2011, 11:18 AM   #5
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if you get rid of that stupid foam tape GM used then it will never come back. for mine i just waited too long to do anything about it and sealed my cars fate in the process
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Old 03-04-2011, 11:20 AM   #6
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That comes from spilling ethanol.
Shouldn't rust it. I've spilled tons and never had an issue. From what I hear it'* the way GM designed it and put some foam etc behind there to hole water and rot the body.
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Old 03-04-2011, 11:31 AM   #7
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absolutely correct Bill although the gas sure doesn't help the matter any
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Old 03-04-2011, 02:50 PM   #8
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Shouldn't rust it. I've spilled tons and never had an issue. From what I hear it'* the way GM designed it and put some foam etc behind there to hole water and rot the body.
X3 Bill. There is foam tape between where the inner and outer sheet metal panels come together that acts like a sponge; it traps water and initiates the rust from the inside out. I had rust bubbles under the paint before it even broke through the surface of the paint. If it was a spilled gas issue it would have rusted from the outside in. The guy that did mine put in some beads of sealer to direct the water to a couple of extra drain holes he put in the inner panel.
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Old 03-14-2011, 12:22 AM   #9
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Same thing here on a 2003, rusted from the inside out just ahead of the filler door centered on the flange of the inner panel behind the body. Poor design.
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Old 03-14-2011, 09:08 PM   #10
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Mine has the rust also. Foam tape and the hole under gas door doesn't help.
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