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 Post subject: Gas Filler Rust Repair
PostPosted: Tue Jun 03, 2014 1:47 am 
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Joined: Fri May 11, 2012 6:09 pm
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Year and Trim: 2004 Bonneville GXP
Gas filler rust is getting nasty, and i want to fix it before it creates a hole. body shop i go to want to chop off the entire quarter panel and weld back on. this is very expensive and probably will cost more than its worth. anything i can do to stop the rust?

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2004 Bonneville GXP- Greystone Metallic
1999 Olds Intrigue GL- Old and Busted
1999 Ford F250 Super Duty- 7.3l Diesel
1972 Chevy C10- 454 Big Block-
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PostPosted: Tue Jun 03, 2014 9:39 pm 
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Joined: Thu May 29, 2008 7:52 pm
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Location: Maryland
Year and Trim: 2002 SSEi
2004 Bonneville GXP
I found a body shop to do mine for $700. Harofreak got me a nice patch panel for $125 shipped. Any other fix like bondo or such will only rust through again. If you do get the metal patch done, use silicon sealant to seal up the crevices inside the gas door so no more water gets in. And have the body shop coat the inside of the patch panel where water is trapped and the rust starts with rust bullet before installing it.

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2004 Bonneville GXP 62,000 miles purchased 04/13
2009 G8 GXP PBM, M6 9580 miles, no mods, sold 08/15
2009 G8 GT SBM 36,000 miles, modded 430 whp
2002 Bonneville SSEi 203,200 miles (sold 3/2014)


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PostPosted: Wed Jun 04, 2014 2:31 am 
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Year and Trim: 2004 Bonneville GXP
well it has 143k miles on it, new HG and bolts 17k miles ago. id like this to last another 5 years. I saw a guy use lead to seal it, looked good. i know them wanting to replace the whole quarter is going to be crazy expensive. i dont know why they cant just cut the entire gas filler out down the the fender well and replace with another. Im getting a quote for front bumper cracks and rear bumper clear coat failure, and the rust. im going to say screw it with the bumpers. i might try and tackle this myself. i worked in a body shop for a while and am a mechanic currently. its a nice car and the only really nasty spot is the rust.

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2004 Bonneville GXP- Greystone Metallic
1999 Olds Intrigue GL- Old and Busted
1999 Ford F250 Super Duty- 7.3l Diesel
1972 Chevy C10- 454 Big Block-
1967 Chevy C10- 350 SBC


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PostPosted: Wed Jun 04, 2014 2:28 pm 
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Location: CHICAGO
Year and Trim: 2006 STS-V, 2004 GTO, 2009 G8 GT
About $500 - $700 is about right for a correct repair.

This is a common GM problem on W & H Bodies, so most competent Body Shops probably can do this blindfolded.

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Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2015 Chrysler Town & Country Limited Platinum: Mommy's NEW RGC
2007 Chrysler Town & Country Limited: Daddy's beater affectionately called the Rolling Garbage Can or "RGC" for short
2009 Pontiac G8 GT: L76, Sport Red Metallic
2009 Chevrolet Impala SS: LS4 V8, Victory Red
2003 Chevrolet Suburban 2500: Doeskin Tan - new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck


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PostPosted: Wed Jun 04, 2014 10:43 pm 
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Joined: Thu May 29, 2008 7:52 pm
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Location: Maryland
Year and Trim: 2002 SSEi
2004 Bonneville GXP
See this thread that I posted a year ago

http://www.pontiacbonnevilleclub.com/forum/post373100.html?hilit=rust#p373100

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bobgto65
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2004 Bonneville GXP 62,000 miles purchased 04/13
2009 G8 GXP PBM, M6 9580 miles, no mods, sold 08/15
2009 G8 GT SBM 36,000 miles, modded 430 whp
2002 Bonneville SSEi 203,200 miles (sold 3/2014)


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