Found some rust - advice

[ross_jsy]

Pretty gutted, cars never had any welding and I could have sorted it 5 years ago when it was just a slight nick in the paint, but oh well!

Started off as just this:



But using Pete's favourite rust detecting implement it opened up to this:



So what's the best way to deal with this? Hoping it's not a scuttle-ectomy as there is no one over here I would trust to do it correctly

Cheers

Ross

[maxfield]

I had pretty much the exact same hole. I chopped it and put a little repair piece in. I did remove the windscreen to paint it after but not needed. But it does depend how good your steel work is.

[rich318i]

going by your hair ross im sure your used to abit of rust

[Rav335uk]

That's not the end of the world Ross.
As max, cut out a piece, weld in another mate.

[Speedtouch]

Indeed. A Dremel, file or similar could be used to create a squareish hole then a little piece of steel MIG-welded in.

Or you could, of course, resort to aluminium mesh and some filler, or fibreglass resin, seeing as it's such a small hole.

[rich318i]

dig it out !!!!

[ross_jsy]

That's not the end of the world Ross.
As max, cut out a piece, weld in another mate.

That's a relief, was panicking. Rust has never featured on any of my previous chariots.

I think I'll give it a go myself

[maxfield]

I think I cut it as a triangle piece which was easiest, mig welded back in, ground back and a skim of filler. Nobody would know and hasn't come back. It was about 3 years ago since I did it

[rich318i]

if thats all the rust you can see id check out the roof and see if that going too

[rich318i]

going by your hair ross im sure your used to abit of rust

Come on!!! funny comment back please

[ross_jsy]

I'm fairly sure I would have spotted some rust a while ago Rich...



I have known the bubble was on the scuttle since I bought it, but never bothered with it. 5 years in the garage and it's got a lot worse.

Unlike most "rot free" cars, mine has been down to a bare shell and I can safely say this is the only patch

[rich318i]

5 yrs in the garage and you comment that why my engine is taking so long..... lol

[ross_jsy]

5 yrs in the garage and you comment that why my engine is taking so long..... lol

Unlike a basic engine rebuild, my cars been fully stripped, modified and built up, cost has been the biggest issue. Touch different

[rich318i]

well in the mean time have been doing the shocks and other bits to help. Now all the money is for the engine and ive only had it from November and did the M52 3 yrs ago this year in july.

M50 manifold, S52 cams, BBTB 68mm, CDA air filter.

NON remaped

Remaped once the engine is done and a few more bits to bring the power up

[Demlotcrew]

It looks like its had a repair there before, get looking inside for more.

[ross_jsy]

Doesn't look like there has been but I'll hit it with a wire wheel and see what I find

[Gert_8]

Harrow, Rossy, One-Hung-Low waiting to recycle that!

Patch it up, mate.

[ross_jsy]

Pete has been furiously PM'ing offering it in exchange for a toaster

Better borrow a mig then, need to weld in my harness mounts anyway

[Demlotcrew]

I can see filler and a masking line, the scuttle has had paint 100%

[ross_jsy]

The front wing has had paint, no filler on the scuttle though?

Anyway, I had this morning off and I was feeling brave so cut out to fresh metal which left me with this:



Made a template out of card:



Cut out a piece from an old boot lid I had knocking around:



And after some forming and shaping I ended up with this:



Now just need to borrow or rent a mig and tack it in place

[Rav335uk]

There you go, didn't take long now.

[Gert_8]

Skillz innit!!

Pony will be asking you to fill in his hole - that's how it all started with Pete, so Diable says.

[Speedtouch]

With such a small patch in an 'awkward' area, I'd be tempted to bond it in using epoxy resin or similar; MIG welding will probably blow holes through, and end up being rather messy...

[Simon13]

you need to get the wiper grill off and run your fingers in there. It will be rusty or flaky no doubt. Once repaired this will need a does of waxoyl to keep it nice. The scuttles rust from the inside out as do alot of other areas in e30s now. Plus its a purpose wet area. Its where you can't see it that can be tricky.

[ross_jsy]

Epoxy resin it's not a f00king Morris Minor!

Cheers Simon, will do. Was going to ask what is the best way to protect? Wax oil the cavity since it's open, then prime the area to be welded with weld through zinc primer?

[Gert_8]

Epoxy resin it's not a f00king Morris Minor!

Cheers Simon, will do. Was going to ask what is the best way to protect? Wax oil the cavity since it's open, then prime the area to be welded with weld through zinc primer?

Careful Rossy, your beginning to sound like Polsta!!

[Speedtouch]

Many modern cars have bonded on parts. It's only a wee patch, and there's a support section underneath it, so epoxy resin would work fine.

But, to each their own...

[ross_jsy]

Better watch yourself Gert, I'll be PM'ing mods telling them you bully me

Yes Maurice, resins have their place in car production, but as a "proper" repair method it's not really suitable for here. The metal is thick enough to stitch weld and then grind back

[Speedtouch]

Sure, that's the 'proper' way of doing it. Just a suggestion as to an alternative method.

[Gert_8]

Is that the correct place for the Ariel?

[DanThe]

Flick the grill out and get some more paint off for a start, you might need to make a bigger repair piece, a magnet on the underside will hold it steady while you weld it up, no paint/primer will stand up to being welded so just clean the steel up as much as possible, if you have small hands you might be able to get in and scuff the underside up with some emery after welding, then just brush some etch primer on, 2 pack preferably.
You can spray the waxoil in from the grill hole once its all dried, give it a week to air dry

[ross_jsy]

Awesome

I'll get Frenchie in there, he has the hands of a child

[DanThe]

Lol

[Gert_8]

Awesome

I'll get Frenchie in there, he has the hands of a child

If Frenchie is coming, can I bring my sequinned glove, please?