Rust Returning

[crazycuda]

Anyone ever have the problem of rust out on a new panel. Put new 1/4's on my cuda, (factory coated with e prime) about 3 years ago. Did the usual prep ground welding areas, sprayed with weld through primer. after all was said and done coated both sides with dp40 then painted. needless to say the courners where i welded are rusting and bubbling. Did i miss a step?

 

[rex]

Sounds like you did the basics right but the initial prep is the key.The weld through primer helps alot but both sides of the area need to be cleaned spotless and sealed up.Getting down in those tight spots is a real chore but if you do miss a spot it will come back later like you're experiencing.The only real way to clean welds is sandblast both sides to clean away any impurities in the weld and all the heat damage but there are places that are a real nightmare to get and seal.It sounds like those spots had a speck of crap left and finally creeped out.Isn't this stuff fun?Sorry man