I have noticed some rust around the jack point plugs on my 1989 300te... Pulled the plugs...the rocker panel coating had worked loose, rust has begun underneath it...pitted, not broken through. I think I can STOP it now if done right. How do I neutralize the rust, what do I coat it with, and what is the stuff that is on the rocker panels (pliable coating) that I can re-apply???

I had a similar problem with my 84 190E, I slowed it down but could never stop it. Every year I would remove rust and recoat the area until the day I traded the car in.

I'd suggest looking at www.eastwoodco.com for restoration products. They offer products designed to stop rust and restore the original finish. The other option would be to find a resto shop or body shop that know's how to deal with this.

Good luck and make sure you check the area on a regular basis to insure it doesn't reappear.

__________________
Afshin

Current:
02 C32 AMG

Previous:
92 500E
84 190E 2.3 5 Spd

I had a 1975 450SE that I had to completely replace the right side rocker panel (outer - there's 2 of them, an inner and an outer). What happens is the water/salt (winter here, anyway) works its way behind the plastic wheel-well guard and ends up rusting a hole in there. Water, now admitted to and sitting inside the tubular rocker section, then rusts holes from the inside out.

Also, water can penetrate from the inner panel as well (snow, water dragged inside on your feet will soak into the floormat padding and eventually rust a hole). I had a leak in the windshield somewhere that let a tiny trickle in that ended up in the rocker channel.

The sunroof drain tube also runs by the rear of the rocker, and will overflow into it if plugged.

Finally, as you've noticed, the jack tubes can get wet and eventually rust a hole into the rocker channel tube, admitting more water and the certain rust to follow. Same if you let the coating deteriorate and the metal gets exposed.

Obviously, you need to remove all surface rust from any affected area, repair as needed, prime, paint, and coat with the correct stuff, then paint again if needed for color coordination.

Old fashioned grinding is one way to remove the rusties. I've used a metal prep solution, from the local bodyshop supply house, that also does wonders.

I've had excellent results with 3M Flexible seam sealer, and various products generally sold as rocker panel coating or 'rock guard'. You can apply ordinary undercoat to unseen areas too.

__________________
1986 560SL
2002 Toyota Camry
1993 Lexus

donbryce, how much did it cost you to have the rocker replaced?
I have the same problem on my 116 on the same side.
Thanks
David

__________________
_____________________________________________

2000 Honda Accord V6 137k miles

1972 300SEL 4.5 98k miles

_____________________________________________

The panel was an aftermarket patch piece, about $75.00. I did the work myself, in about 7 hours. Bodyshops charge an arm and a leg for this work, unfortunately.

__________________
1986 560SL
2002 Toyota Camry
1993 Lexus