Superb writeup!

 

So, what's the best way to take care of the minor rust? Do I have to sand and re-primer, or is there a "paint-friendly rust removal" product on the market? (I have a minor rust problem in my trunk, too... but for a different reason.

 

There is heaps of products out there.. i rubbed mine back with steel wool and then brushed on 'rust eater' which can be found at any hardware store.

 

Thank you for the post. I would have never thought to even check for this. I'm gonna go look this evening when I get home.

 

Just something to add.. maybe to the OP.

You can seal it from the inside, just like you did from the outside, and it will work aswell, and you dont have to take off the bumper. I actually used plumbers putty, but the same stuff used above will work just fine also. I didnt feel like taking off the bumper, so I just took out the panel, and went around the inside edges. No more water!!!

And another thing. If you do have rust inside the well, make sure you use something like a "rust convertor" or something that will get rid of the rust first (even sanding it down to the metal, then using primer, and some kind of paint.) If you just paint over rust, it will continue to eat away at the metal until one day, there will be a nice hole eaten through.

The best stuff for rust short of cutting out and welding a new piece in is stuff called POR-15. Its pretty expensive, but it works. But if its just a little surface rust, I would just sand it a little first, then use a rust converter, and then paint.

 

linking to the FAQ

 

 

I have to check and see if I have this going on. Is it tough/involved pulling the trunk panels out? I have the service manual as reference. Just wondering if there are any tips worth knowing.
Also I would like to second what someone else said about rust and POR-15. I have only used the putty. They also have a paint in 3 colors I think White, Black and Grey as well as a zinc spray pre-treatment.
To the OP, great post, good info, Thanks! I hope you got EPS straightned out also.

 

Good job, I saw a Lime Green S at a dealer with this, he refused to believe it was a vent behind the bumper

 

Thanks for the write up and great pics! I have the same problem. I had almost HALF that sub area filled with water untill i notice some paper i left in truck we wet and stay wet. Luckly no rust for me. Now I know where and how to fix it.