Well I took off my panel the other day and ground it down to bear metal, I'm planning to repaint the whole thing, and it looks like my PO had the same problem. They neutralized the rust and put fiberglass behind the rust holes. Does anyone think that should just get rid of the fiberglass and weld metal back into the rust spots or will the fiberglass hold? I've never used it for a repair.

P.S. sorry for sniping the thread.

Has anyone ever had rust bubbles develop under the paint of the air intake grill? I have some that seem to be small... but I'm wondering what I should do next..? Any ideas? I don't mind having to sand anything down or ruining the paint, I just don't want anymore damage to be done.

Take the grill off and have it media blasted and repainted. You lucked out because the rust bubbles are on a removable piece of bodywork.

While the panel is removed, make sure to check the inside of that area. You should also remove the windshield wiper motor and check the hidden areas.

Rust bubbles, anywhere on the car, usually indicate another problem deeper in the metal. But, sometimes you luck out and it's simply on the surface.

-- M

Yes, you should replace that old foam. The reason it's there is to stop vibrations in the cowl at high speeds. Any foam that doesn't hold water will do in there, just use the old bit as your template for size and thickness.