Corrosion on Powder Coated Chassis - Normal?

[Mister Val]

Working on my build today I noticed quite a bit of rust on the inner surfaces of the chassis. I've only had it about four months... Is this normal? Anything that I should be doing to mitigate it?
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[gbranham]

My Mk3 years ago had the same inside the channels. I didn't do anything with it. That outside bit behind the door hinge...I don't remember seeing anything like that. Might not be a bad idea to scuff off the surface rust and hit it with POR-15. Wear gloves. The only thing that gets POR-15 off your hands is time.

[proeagles]

Sadly the powder coat doesn't make its way inside openings. Too bad the ends aren't sealed. Seems like an oversight considering all the trouble and expense.

[Fman]

Exterior rust on area that should have PC'd is not normal (which appears how it is in your first pic next to the door hinge), as others mentioned inside the frame not much can be done about that other than coating with something you can reach it with. Definitely would want to address that area next to the door hinge that should not be rusting.

[proeagles]

I wonder if all the frames come like that? Definitely should be end plated and sealed IMO.

[michael everson]

That area near the door hinge is like that because the powder coating rack slides in that tube.
Mike

[cv2065]

Powder Coating doesn't get into those channels unless you specifically request them to do so. And even then it's a difficult area to coat. It's just surface rust, so I doubt it will ever pose a problem.

But, if it bothers you, you can buy plastic caps to close them off from Mark at Breeze. Eastwood also sells an internal frame coating that has a long tube on the aerosol to get inside. Might want to hit it with some rust encapsulate first. Rustoleum makes a good one.

https://breezeautomotive.com/shop/finishing-plug-for-2-square-tubing/

https://www.eastwood.com/eastwood-internal-frame-coating-14oz-aerosol.html

https://www.amazon.com/Rust-Oleum-Automotive-248658-10-25-Ounce-Reformer/dp/B003HG48AC/ref=asc_df_B003HG48AC?tag=bingshoppinga-20&linkCode=df0&hvadid=80470559180672&hvnetw=o&hvqmt=e&hvbmt=be&hvdev=c&hvlocint=&hvlocphy=&hvtargid=pla-4584070137886944&th=1

[J R Jones]

Powder coat is a cosmetic coating not specifically anti-rust. If rust is, or gets under it, the coating will lift/blister.
A production process utilized specifically for corrosion protection is also applied with an electric charge (EDP) to the part that is dipped in a liquid medium. If internal chambers hold air, the part is rotated to coat all internal surfaces. This coating is used on marine parts for salt water protection, but not all coatings are UV protected and need a top coat for cosmetics.
jim

[Mister Val]

Appreciate all of the feedback, you guys! I ordered some of the Eastwood spray, and it'll be here later in the week. It looks like it neutralized any existing rust (will brush off what I can first) and is able to reach deep into the frame. I had been wondering how I would apply POR15 more than a few inches in.

Will report back when I've applied it, but it looks fairly easy.

[Mister Val]

Hello! It took me a while to finally update this thread... but I used the Eastwood Internal Frame spray, and it seems to have done a great job. I cleaned out what rust I could reach with a wire brush first, then sprayed the length of the offending tubes. The spray comes with a long extension which applies in a 360* pattern, so it can reach all the way to the middle of the car. Coats well, and supposedly will penetrate any existing corrosion. I used less than one can.
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