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Hot take: a $9 tube of seam sealer saved a quarter panel I was about to cut out
I had a rust bubble the size of a half dollar above the wheel arch on a 2011 Escape and my first plan was to cut the whole lip out and weld in a patch. Before I did that, an old guy at the parts counter in Fresno told me to dig the rust back to clean metal with a carbide burr and then fill the gap with self leveling seam sealer instead of mud. I ground it out with a 1/4 inch burr, hit it with epoxy primer, laid the sealer in two thin passes with a day between them, then blocked it flat and painted over it. That was 7 months ago and it hasn't shrunk, cracked, or shown a single line under the base coat, and the customer still hasn't come back about it. I'm not saying it works on a hole you can push a finger through, but on shallow rust it beat the welding I had planned. Has anyone pushed this trick on a bigger area than a wheel lip, or does it always bite you later?
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