[scream]Fukcing fuming[scream]

[Andyboy]

I would wire bush it and give it a bit of Waxoyl before putting the headlining in and saying bollocks to it. To repair it properly means a new roof. What you CAN do however - and a mate of mine did this on an E36 saloon - is to cut the sunroof cassette out, cut an inch around the sunroof aperture and stitch weld a steel plate in. A skim of filler later, some skilled rubbing down and a coat of paint before fitting a non sunroof headlining. It's a very viable option you should think about and the rust won't ever come back.

[bss325i]

Or he could do what i had done, the only cost was the labour cause a second hand roof doesn't cost much. Check page 7 of the link in my sig.

[lenny-d]

well the way i look at it is if it happened to your car it can happen to a donor for the reshell

if you fix it at least you know that its sorted and will do another 15 years or so

she's been driving ok and you're only in a panic cause you've found this but doesn't mean that she has to be scraped

sort the arches stick the old liner back in and throw a couple of quid aside each week and hit it all guns blazing and you'll have one of the tidiest cars on the zone

[tailoutcharlie]

well the way i look at it is if it happened to your car it can happen to a donor for the reshell

if you fix it at least you know that its sorted and will do another 15 years or so

she's been driving ok and you're only in a panic cause you've found this but doesn't mean that she has to be scraped

sort the arches stick the old liner back in and throw a couple of quid aside each week and hit it all guns blazing and you'll have one of the tidiest cars on the zone

well said, your cars to luuuurvley to kill.

[eko]

Right ive decided!
Im going to try and get to a breakers this week and stanley knife a few headlinings till i find one thats not rusty.
Armed with a hammer/chisel/hacksaw/tinsnips ill attempt to chop a piece out to jigsaw back into mine.
Ill then start to cut away at mine to get rid as much of the rusty section out without going flush to the roof skin,maybe leave a good 10mm or more of the old piece,does that make sense??
Then ill start to clean up the new piece and measure and cut to size ready to be stitch welded back in.
Assuming i get this far,will i be ok to go along the whole join with fibreglass to seal it up?
Obviously ill rust proof/paint the whole thing.
Cant fit the standard roof lining back in as its fooked so will have to fit the Black anyway,might as well finish what was originally the plan

In the meantime i have my eye on another E30 on Ebay.If that pays off then ill just carry on and scrap this and use the best bits on the other but upto now im going to give it a go!

Thanks to everyone who has commented,youve all inspired me

Oh forgot to mention-My welding skills are very limited and i mean very,good time to practice though eh

[320Touring]

Nice one Tony

[tailoutcharlie]

good luck pal

[eko]

Quick pic ive just taken showing the area im thinking of cutting out,this should see 99% of the rust gone.
Im thinking if i put a tack on each corner of the new section then just go along and spot weld all round then fibre glass over it all,reckon it will be good enough?

[lenny-d]

glad to hear it, it will be worth every penny

[padi]

Good luck with it all mate, sorry to hear about the rust. If you need a hand with anything ill try, but not very practicle...Lol. Anyway hope it all goes ok.

[eko]

Thanks guys,going to need the luck

[Sanchez]

well good luck from me. Ive had parts of you and no you no your stuff.

its a beautiful car that you've work loads on, you no you wana keep it going.

[AndyG]

nothing is financially economical where old cars are concerned, as you very rarely get back what you spend, so look at it in not how much it can repay you cash wise (because in reality that will be very little) but how much enjoyment and the type of abilities it will give you over the next few years of ownership. If you repair it at least you'll know its done and thats one less job to worry about.

Who knows that if you buy another, you'll end up doing all this again?

[tbmw]

sorry to hear about the rust tony
good luck with the repair, will be watching closely as i've found the same prob with mine

[Jesus325iTouring]

Quick pic ive just taken showing the area im thinking of cutting out,this should see 99% of the rust gone.
Im thinking if i put a tack on each corner of the new section then just go along and spot weld all round then fibre glass over it all,reckon it will be good enough?

I reckon so personally.

Dude,if you want to cover cost of postage,i'll post you a fibre glassing kit,you don't want to be using the pathetic crap they sell in Halfrauds,the resin is crap and the fibre glass is like tissue paper.
I've got a bloody great roll of 450gm2 fibre glass and a barrel of industrial resin and catalyst,this stuff is the bollocks.

If you want me to make up a kit for you,PM me your address etc.
Postage would be about a fiver I guess.

[eko]

^ Rodger you fooking hero
Ok if i PM once i get the new piece?
Would rather get that first then i know its all systems go!
Thanks mate

[eko]

Ive never even used fibreglass so think ill need instructions too
Although ive seen Chip Foose do it

[Jesus325iTouring]

^ Rodger you fooking hero
Ok if i PM once i get the new piece?
Would rather get that first then i know its all systems go!
Thanks mate

No worries

[lenny-d]

sure he makes it look easy so it'll be a piece of p155

you know your doing the right thing just think of the satisfaction(sp) you're going to get once you've finished


ps would offer a hand but you'll need to pay travel and get me a sleepin bag for the sofa

[Jesus325iTouring]

Ive never even used fibreglass so think ill need instructions too
Although ive seen Chip Foose do it

PMSL............I'll add some instructions too

[eko]

Ive never even used fibreglass so think ill need instructions too
Although ive seen Chip Foose do it

PMSL............I'll add some instructions too

[topspark]

Eko ,

Just been reading through this thread !!!! Seriously gutted for you. Gonna have a look at mine now as soon as!!

Just a thought , but mate of mine uses this company for rust cure / protection stuff he really rates it. I sent for the catalogue last month and they sell lots of goodies for curing / stopping rust.
good luck

http://www.frost.co.uk/productList.asp? ... stCat=Rust

lee

[eko]

Eko ,

Just a thought , but mate of mine uses this company for rust cure / protection stuff he really rates it. I sent for the catalogue last month and they sell lots of goodies for curing / stopping rust.
good luck

http://www.frost.co.uk/productList.asp? ... stCat=Rust

lee

Thanks for the link mate but can i not just use the bottle of Kurust ive got in the shed?
Its about 8 years old though

[topspark]

Thanks for the link mate but can i not just use the bottle of Kurust ive got in the shed?
Its about 8 years old though

Yes i dont see why not , just thought if you needed any advice on killing rust that you cant always get to. Wifes uncle has been restoring a VW camper and he used some stuff in a spray can that he sqirted into seams that were bleeding rust out onto his white paint!!! Let it dry off and refilled the seams and repainted. Hey presto no rust now for the last year. Just thought it may come in handy . Ive not even started work on my car yet dread to think what im going to find . As yours mines looks good from the outside , but you never know whats under the next panel you remove.!!!

[bss325i]

The only way to sort this out properly is to cut it out completely or it will just get worse! Rust is like cancer, you need to cut it out or it will spread! None of this fiberglass or rust treatment stuff, just replace the panel, its a great car and is worth doing!

[topspark]

The only way to sort this out properly is to cut it out completely or it will just get worse! Rust is like cancer, you need to cut it out or it will spread! None of this fiberglass or rust treatment stuff, just replace the panel, its a great car and is worth doing!

bss325i i totally agree . Thats how i always tackle it , but some times you cant get all of it due to poor location , i also use rust proofing on metal after ive welded just to keep it at bay!!!

lee

[eko]

The only way to sort this out properly is to cut it out completely or it will just get worse! Rust is like cancer, you need to cut it out or it will spread! None of this fiberglass or rust treatment stuff, just replace the panel, its a great car and is worth doing!

Barry i get what you are saying,your a pro at this stuff and i do value your opinion and advice.
I was planning on cutting more or less on the line in the pic above thus giving a good couple of inches clearence of the rust.The only place i wont be able to clear all the rust away is above the drain pipe in the corner,this is where it will get tricky but as it will be `above` the drain tube,as long as the pipe is clear and kept clear then surely it wont be much of a problem?

Bet you hate us `non proffesionals` dont you

[bss325i]

The only way to sort this out properly is to cut it out completely or it will just get worse! Rust is like cancer, you need to cut it out or it will spread! None of this fiberglass or rust treatment stuff, just replace the panel, its a great car and is worth doing!

Barry i get what you are saying,your a pro at this stuff and i do value your opinion and advice.
I was planning on cutting more or less on the line in the pic above thus giving a good couple of inches clearence of the rust.The only place i wont be able to clear all the rust away is above the drain pipe in the corner,this is where it will get tricky but as it will be `above` the drain tube,as long as the pipe is clear and kept clear then surely it wont be much of a problem?

Bet you hate us `non proffesionals` dont you

I dont hate anyone fella! The panel replacement was not done by me, i just know how it was done. Cant take credit for someone else's work.

[OBs]

Jenolite is the best of the 'Off the shelf' rust treatment products Tony, You will need Etch primer to (*Cough) all ready sorted

And a nice woolly blanket (Old one) Fold this up neatly on top of the roof and keep a constant supply of cold water running over it (If you can stop it coming in??)

Ill see what I can do to help...

Brace your self though!

[eko]

Jenolite is the best of the 'Off the shelf' rust treatment products Tony, You will need Etch primer to (*Cough) all ready sorted

And a nice woolly blanket (Old one) Fold this up neatly on top of the roof and keep a constant supply of cold water running over it (If you can stop it coming in??)

Ill see what I can do to help...

Brace your self though!

All freebies welcome

[eko]

Andy,still need that front bib too,any joy

[OBs]

Andy,still need that front bib too,any joy

Ill look in to it

[eko]

Andy,still need that front bib too,any joy

Ill look in to it

Ok mate

[munky30]

Right ive decided!
Im going to try and get to a breakers this week and stanley knife a few headlinings till i find one thats not rusty.

I havent got the headliner out of the breaker yet... But I will tomorrow... will take some pics of the roof and post them here.

If its up to standards, you can have it for nothing. Gratis, free... The shell of this is just going to be scrapped so you are more than welcome to come and angle grind away at it.

Very happy to hear you're going to fix it mate, would have been sacrilige to give up on it. As ever, if you need a hand.....

[eko]

Cheers joe that would be cool!
I can probably get hold of a petrol disc cutter,would make it easy 10 minute job
Keep me posted mate,could possibly get there Wednesday?