Help Needed For Rust Repair

[satisfyingcrunch]

Hey guys, i've just got myself a Ke70, and there is quite a bit of rust that i wasn't able to see until i stripped the car down. I'm quite new to this and really this is my first time working on a car, so i'm not too aware of how to fix all rusted situations. So far I've removed some surface rust and minor rust here and there, but this rusted area was actually behind the left hand side fender.

 

 

I saw that it was rusted from behind, so went and stripped the interior to investigate and found this.

 

 

 

 

 

 

 

Its quite a tricky spot and i really don't know how to go about this. Any help would be greatly appreciated

[It's_AUDM_Yo]

Is it too the paint where you can just poke through the rust with your finger?

 

If it isn't I would probably just buy rust kill and give it a few goes with that, They sell it at Supercheap and the likes.

[satisfyingcrunch]

There are some bits were it has rusted all the way through, a few small holes maybe round 5mm to 10mm nothing too big. Apart from that its still pretty solid. So i don't grind most of the rust off, just slap some rust kill on it?

[B.L.Z.BUB]

Get in there and scrape as much as possible off, doesnt need to be bare metal. RustKill can be painted on rusted surfaces as long as all the flaky stuff has been removed. Its only a temporary fix, if its a car you wanna keep for years and years at some stage you'll need to strip the dash out to repair it properly.

 

Also its probably rusting from a leak. Hunt that sucker down and plug it.

[altezzaclub]

Yep. Actually, wire brush time more than grinder.

 

...and then put fibreglass over it if you want to add some strength back in.

[satisfyingcrunch]

hey guys, thanks for the tips. I've grinded it down a bit and still to really give a good brush. What would be a proper repair as i've already stripped the entire dash out? I do have access to a welder btw.

 

@altezza so remove as much rust, apply on rust kill and slap on some fibre glass?

[B.L.Z.BUB]

if you can find another car and cut out the section you need and weld it in, if not find some plate and weld it in.

May as well do it properly, the fibreglass option is effective but it will need to be repaired again at some stage, especially if it starts to leak again.

[satisfyingcrunch]

Alright thanks. Looks like quite a difficult job because i can see rust between the 2 panels. Also, i'm not too sure what you mean by leak. Is it making sure there's seam sealer and stuff?

[altezzaclub]

Is the windscreen leaking there?? or the vent system??

 

If you can get in there with a welder then welding plate over it is better than f'glass, but if you can't get at it then f'glass is better than nothing. It grips well to rust holes and rough steel.

[satisfyingcrunch]

Sorry i'm not sure what you mean by leak :S.

[japlish]

That's one of the hardest sections to fix on these cars so if its your first time then you're going to struggle....I sound negative but its the truth, I've had to do this twice and you have to go from the TOP not underneath which means your going to have to either cut or drill out the metal from the top and work your way back from there.

 

That's how far in I had to go and I have already made a new heater vent in that pic

 

And this it all back together:

[altezzaclub]

Sorry i'm not sure what you mean by leak

 

When it rains. If water gets into the car at the corner of the windscreen it can follow the path shown down that area. It may have leaked for a year or two in the past and then had the leak fixed. The water that goes into the ventilation grille in front of the windscreen when it rains may also find its way inside.

 

There seems to be a water trail where I've drawn the circle. It is easy to see in your other photo.

[satisfyingcrunch]

@Japlish

 

Thanks man. I was actually thinking of hacking away panels around the rust to get better access to it earlier, but being a first timer i wasn't sure if my methods were correct.

 

@Altezza

 

Thanks man, i'll go sort out the leak.

[styler]

Best is to cut and weld that degree of rust, next option for less rust would be media blast and seal,

then lastly for surface rust can wire brush & use a chemical remover/converter but must be careful

with the product selection and application.

Edited June 13, 2013 by styler

[satisfyingcrunch]

Also, i'm just wondering what kinda of metal i buy if i am cutting and welding. Do i just buy sheet steel or can i use aluminium also?