Optimistically, I think well how bad can it be? Well I turned the panel over and started grinding and found 1/4" of filler and then "brown primer" (deeply pitted rust). 
I kept grinding at the rust and more holes and potential holes began to appear. Disgusted, I grabbed the passenger side panel. Same story. So much for the rust free SoCal car I was bragging about. At least it is easily accessed. Now, I know that I could probably sand-blast the panels, silver solder the pin-holes, chemically neutralize the rust and epoxy prime the panels but.... The referenced chemical reaction doesn't stop until there is either no more Fe (ie car), H20 (water which is in the air (especially in the Carolinas)), or O2 (can't move the car to another planet).1. 2Fe(s) + 2H2O(l) + O2(g) ==> 2Fe2+(aq) + 4OH-(aq)
2. Fe2+(aq) + 2OH-(aq) ==> Fe(OH)2(s)
3. Fe(OH)2(s) =O2=> Fe(OH)3(s)
4. Fe(OH)3(s) =dehydrates=> Fe2O3.nH2O(s) or rust
So, I think the best course is to replace the rockers with new ones. Here is where I need your advice. Should I go with the reproduction steel panels and epoxy seal and coat the inside with Por or something equivalent or should I try the ABS ones(no Fe
) and add a flexible additive to the paint to avoid cracks. Anyone with experience here? Can anyone comment about the quality of the replacement panels?
