I started sanding the door jamb and found a few small areas that was either seam sealer or rust bubbles around the left hinge area on the A pillar. Once I started grinding I could see that it was rust. This is one area that you want to look at before your car is painted because Brian has had to repair a few. This is what it looked like after I ground it and poked around with an awl.
There is multiple layers of metal and you have to cut each one off until you find good metal. We started out thinking we could patch it.
Brian cut out one layer and this was under it
He decided he needed to cut out around the hinge area
This is how it looked on the back side and we decided that it would be more cost affective to replace the A pillar since I also found rust in the bottom. So I hated to tell Lauren the bad news on Thursday so Aaron ordered a new set (you can't buy just one side) and we had it Friday around lunch time.
Brian had to cut up into the windshield post to find good metal
Brian drilled out all the spot welds and removed the A pillar
He also found more rust
This is how the A pillar looked
Brian marked off the area he wanted to replace and made a new patch
He than cleaned up the welds and applied SPI epoxy with a brush
Since we had both sides and there was so much hidden rust we decided to change the other side also. I sanded and sprayed them with SPI black epoxy