Hello All,

I have a 1996 850 GLT wagon (with 250,000 miles), painted silver metallic. Recently a rust "bubble" developed on the wheel well directly above rear driver's side wheel. Of all the 850s I have seen, I have never noticed rust bubbles forming around the rear wheel wells. I wash the car once a week, and always spray water up into the rear wheel well to remove dirt, so it doesn't trap moisture. My car for the last 7 years has not been parked in a garage, but is outdoors all the time. I'll get the rust bubble fixed in the spring, but I have some questions..


1) What could have caused this rust bubble (it is only on the driver's side)?

2) If I get this rust bubble fixed, does that mean it will only come back again?

3) When getting this rust bubble fixed, is there anything in particular I should ask the auto body shop to do to increase the chances of this rust never returning again?

Thanks to all who respond. I hope this rust is not the beginning of the end of my 850 wagon.

Hugh

I'm wondering if it could have been a leaky window seal that allowed water to run down the inside of the fender panel, rusting it from the inside-out. I don't know exactly how the rear fenders are constructed. Just a thought....

Chris,

Thanks. I'll raise that issue with the auto body shop that ultimately repairs this problem.

Hugh

Hi Hugh,

I suggest that you wire brush the area and paint it with cold (90%) zinc paint
if you can find it. There might be spray cans available sensible for small jobs.

What caused the rust? did something skin that area down to the steel? or is there
any stainless steel nearby that might be setting up electrolysis?

Keep stainless steel away from body parts.

Bill

Bill,

Thank you. I'm a little concerned about scraping the rust and repairing. The surface of the paint is not discolored from rust. The painted surface of the fender is significantly raised, like a bubble or blister. It has grown too since I first observed it. My fear is if I scrap it, I will be left with a hole into the panel. My thought is that to fix this properly, a portion of the existing panel will have to be cut away and a new piece welded in place. Of course this would be an expensive repair.


That's why I'm concerned if this will be a long tern and continuously spreading problem

Hugh

Hi Hugh,

There's little rusting on 850's since I understand the body panels are galvanized.
I wouldn't be so afraid to wire brush that spot, since you could easily make a patch yourself and install with pop-rivets & JB weld and cover it with a little undercoat spray to make it pretty. Bondo is easy as well.

I would be more worried about welding though, since you might fry something
unexpected, such as a wiring harness. Before you weld in floor panels for instance, all the seats and floor mats/rugs, harnesses,etc etc need to be
cleared away.

Bill

Bill,

I may "live dangerously" and try to fix this myself. If I "bomb" then bring it to an auto body shop.

Hugh

Usually caused by a door 'ding' that managed to crack the paint but not dent the metal. This is surface rust. A good sanding down to bare metal, followed by some rust inhibitor, then a coat of primer and silver paint.

Most body shops cannot match the faded paint and will want to paint the entire quarter panel. The cheap shops do not apply rust inhibitors and after painting with water based primer and paint, the rust comes back - I wonder why.

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My name is Klaus and I am a V♂lv♂holic

Klaus,

There doesn't appear to be any contact to the side of the car where the "bubble" has emerged. I'm afraid to sand the bubble down to the bare metal for fear I will leave a "hole". Thank you for replying.

Hugh

The 'bubble' has moisture inside of it, if you do not remove the paint and rust layer, it will grow larger. If the rust is completely through the panel, then there will be a hole and nothing short of welding in a new piece of steel will help.

Wear gloves and a mask if you sand it down yourself. The entire body was zinc treated at the factory, and zinc is quite harmful.

Most of the rust on these cars could have been prevented by an annual coat of paste wax applied in September or October. Especially the rear lift gate on wagons.
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My name is Klaus and I am a V♂lv♂holic

Klaus,

Thanks. I'll follow your advice. I confess, I haven't waxed my 3 Volvos each spring as I usually do. The old culprit: lack of time. I'll just have to find the time now. I'd like this 850 to last forever because it is a stick and they literally "don't make them anymore".

Hugh