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Old 03-05-2012, 12:35 PM   #1
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Default 2003 Gas Inlet Rust Issue

I was wondering how many of you have had this typical rust issue around the gas inlet that you see on a lot of Bonneville’* and grand prixs? Well the rust on mine has gotten pretty out of control. If you have fixed this how did you do it and how well has it lasted for you? I went to a local body shop and they said they can cut it out and replace it with a new section. But there is no guarantee on rust work. They wanted about $1200.00... Replacing the panel is $2800... My car is in pretty good shape otherwise and only has 87K miles on it. I'd like to get it fixed...
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Old 03-05-2012, 01:22 PM   #2
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id get a few other estimates, thats seems awful high especially for someone who cant guarantee there own work.
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Old 03-05-2012, 01:43 PM   #3
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Correct, I planned on getting a few other estimates... I was just curious if anybody else has had this fixed and what their experience was and the cost. Seems high to me also. I asked them if they can do anything to prevent it from happening again..Undercoating, anything, and they said no.
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Old 03-05-2012, 02:07 PM   #4
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Hopefully Sawgunner will chime in. He has some very direct expereince with this issue.
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Old 03-05-2012, 02:13 PM   #5
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you talking about outside on the fender under the filler door?
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Old 03-05-2012, 06:23 PM   #6
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GM used a rubber/foam seam sealer between the inner & outer panels. The foam absorbs water that collects by the gas filler neck and the rust starts between the two panels.

I took some liquid silicone sealer to fill the gap between the panels. The water now "pools" in the filler neck area but does not soak into the foam. Works for now.

I can't say the same about my 92 SSE.

2005 GXP
64,000 miles
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Old 03-05-2012, 06:55 PM   #7
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Sawgunner had the issue on his 2000 SSEi, and it ended up causing major unibody corrosion, to the point he ended up parting out an otherwise near flawless Bonnie. I think his experience is good to note, as to know if the damage is cosmetic or structural.
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Old 03-05-2012, 07:31 PM   #8
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Quote:
Originally Posted by jwfirebird View Post
you talking about outside on the fender under the filler door?
Correct...

Quote:
Originally Posted by bobc997615 View Post
GM used a rubber/foam seam sealer between the inner & outer panels. The foam absorbs water that collects by the gas filler neck and the rust starts between the two panels.
And also exactly correct... The local bodyshop here actaully has a cut out showing this due to it being a big issue. I did get the name of a couple good body shops. One of them says after he cuts that area our and before he welds a new piece in, he would address this foam sealer and undercoat that area. Also spray like a truck "bed liner" inside the fas filler neck to seal that seam... Waiting to actually go see him and get a quote..
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Old 03-06-2012, 09:22 AM   #9
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A lot of people attribute this corrosion to spilling gas in this area, but the post about there being foam between the inner panel and the outer is correct. I had a chance to see mine when it was cut open and that is exactly what the problem is. Cost me $600 to fix it, but a friend did the body work. $1,200 is a little steep, but you are definitely cutting out and removing metal to fix this. Its not an easy repair.

Mine was fixed 2 years ago and I now have some rust bubbles below the section that was replaced. We will take a look at it this summer.
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Old 03-06-2012, 10:31 AM   #10
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Quote:
Originally Posted by 2kg4u View Post
A lot of people attribute this corrosion to spilling gas in this area, but the post about there being foam between the inner panel and the outer is correct. I had a chance to see mine when it was cut open and that is exactly what the problem is. Cost me $600 to fix it, but a friend did the body work. $1,200 is a little steep, but you are definitely cutting out and removing metal to fix this. Its not an easy repair.

Mine was fixed 2 years ago and I now have some rust bubbles below the section that was replaced. We will take a look at it this summer.
... This is not what I was hoping, but it was kind of what I was expecting. Even if it cost me $1000 and the rust comes back in 2 years.. That'* $500\year to not see the rust issue... I will just have to see what a couple other body shops say, but if I can expect it to be back in a couple years... I don't know what I will decide. It'* a shame if you ask me. This car only has 87K miles on it, but I just can't stand that big rust spot on such a beautiful car...
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