Rust On Inner Door
 

On all four doors on the inside bottom where the seam or bend is, is starting to rust. What is recommended? Should I wire wheel the rust off and epoxy/caulk/or coat with something to prohibit the rust?

I have not been able to figure out how to post a picture or maybe I am not permitted to post pictures, but I can send you a picture of the issue which may explain things a little better. I can email them to anyone who would like to see.

Thanks in advance.

its common, ive had it too, once it starts you cant stop it, just slow it down a bit.
I advise not to grind off paint along the entire seam, it will just rust faster. Chip off where it is bubbling and touch it up.

What about something like Por-15, thats supposed to "stop" rust?

Unfortunately it's a common problem on HHR's in the rust belt, GM has covered repairs in the past for several members here, so see your dealer's service manager.

Por-15 does kill surface rust, but you need to get back to base metal by sanding or wire brushing. Once dried, you can paint over the Por-15 with good results.

I've had to get 3 of the doors in my 2009 fixed. One of them has already been back for a second time

My 2008 is in the body shop today to have the repair done for a second time. The dealer agreed to do it as a customer service to me; GM apparently won't cover the repair after the 36 mo. / 36000 mile warranty is up unless the metal is perforated. At first, it seemed to only be rusting where the rubber seal touches the bottom of the inner door but I have noticed other areas now as well. This is a design flaw and should be covered by GM. Haven't had a vehicle rust like this since the '70s.

Thanks for the input, I will give it a try.

My 09 is having the same issue. I only noticed it on the drivers side front but will have to check the rest... Looks like I will be speaking with the dealer to see if they can fix it at no cost to me.. I love my HHR but this rust issue is really disheartening.

I'm disgusted! There's no reason a car these days should rust like this. Going back to the dealer for the second time.

Yep my 08 panel is at the body shop now. Getting both front door and rear hatch done second time. Mine has 70,000 on it and they are still covering it so I can't complain too much. I sure it will do it again ohio uses lots of salt in the winter.