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Old 09-30-2012, 12:28 PM
JamesDean's Avatar
Electrical Engineer
Join Date: Apr 2005
Location: NE Ohio
Posts: 5,021
300D 2.5 Rust Repair, some areas to watch out for

Hey everyone,

This is probably more suited to the bodywork forum but I figured I would post here so that people are aware of this area. This car has no other rust spots on it..

I just got around to fixing some rust spots on my 300D 2.5. I thought I'd post up and warn all you 300D owners. These spots seem like they might be unique to the 300D due to the oil cooler location and the air intake location.

I don't have any pictures of the rust from below the intake area on the passenger side fender but while I was changing my headlights out I spotted it. I knocked out all the old rust and painted over the rest. I'll have to do it up proper later on down the road. It wasn't an immediate threat as it did not open up to the outside as the driver side did.

The driver side spot is just to the driver's side of the ABS block, right above where the oil cooler is located.

My hole was pretty big, so I cleaned it out, coated the area with some Rust Encapsulator, then pop-riveted a piece of metal over the hole and I plan on coating that and then applying seam sealer to both sides of the metal. Finally it will be coated with some rubberized undercoating.

I would have welded it but my welder was out of gas and wasnt in the mood for dealing with it really. This worked out well actually.

The hole:

Rust Encapsulator:

Riveted in patch piece:

That piece was also coated with Rust Encapsulator on both sides, I just forgot to get pics.

Seam Sealer:

Finally, Rubberized undercoating:
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