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Discussion Starter · #1 ·
Hey all, I had cut my stock fenders back due to putting on larger tires a few years ago. Over time those fenders wiggled back and fourth and rubbed the paint off on some small areas. I removed them to inspect and noticed some rust beneath the paint on a pinch seam in the fender well. As you can see from the pictures, there was a decent amount to uncover. On the surface it was hardly visible.

I was planning to cut this area out. There is a small width (about 1.5”) of pinch seam that is rusted. There are large vac type tubes that go to the gas tank behind this pinch seam. What tool should I use or avoid to cut this out? I’m concerned about sparks. Once this is done, I plan to use bed liner to protect.

You can also see that in the rear cargo area the body sealant had separated. I removed it and discovered that it was also doing it in the same place on the other side but there is just a tiny dot under the surface of the paint. Is this common?

Hood Light Bumper Automotive exterior Wood
Brown Wood Automotive exterior Tints and shades Vehicle door
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My 2010 is doing the same thing. Not as bad as yours though. It's on my list of things to get to before it gets bad.
 

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Discussion Starter · #3 ·
My 2010 is doing the same thing. Not as bad as yours though. It's on my list of things to get to before it gets bad.
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this hurts me to cut into it like this. It looks jagged but I am going to smooth the edges down and paint it. Gonna be dry this coming week. It really does seem like some kind of issue because it’s happening on both sides. I just keep telling myself that I can make it look nice and hide it. Battle scars!
I’m taking a break and after that I am going to clean the rust off and break out the grinder to smooth it up. Thank you for your reply!
 

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Not a big deal. I bought a north-eastern JK and it has similar bits of rust and pitting where salt and water settled. I just hit it with a flap disk down to raw steel and hit it with the BBQ paint. For that fender maybe clean it up and prime it, followed by some factory ernge touch-up paint. When you sell it, throw some liners in and nobody will be the wiser. 😬
 

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this hurts me to cut into it like this. It looks jagged but I am going to smooth the edges down and paint it. Gonna be dry this coming week. It really does seem like some kind of issue because it’s happening on both sides. I just keep telling myself that I can make it look nice and hide it. Battle scars!
I’m taking a break and after that I am going to clean the rust off and break out the grinder to smooth it up. Thank you for your reply!
Post some after pics of the repair
 
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