This is how I deal with rust

[Carbon]

My 2002ti is currently on it's side, making underbody repairs easy, so I thought I would tackle a rust spot under the rear seat while I am at it.

Here is the spot, its rotten right through:

Starting to shape a patch:

Further shaping:

Test fitting:

Cutting rust out:

Tack welding it in place:

I am going to weld the whole thing up tomorrow and grind it down.
It is a long and tedious process to weld, and I am tired tonight.

Regards
Jacques

 

[Mamba]

nice job

 

[Philip Foglar]

Quite aggressive rust combat!! Great work!! :thumbs:

 

[Carbon]

I got the time today to finish the welding and grinding.
The most time consuming is tack welding as I do 3 tacks and then wait for the whole panel to cool, and then do it again. Took about 2 hours doing other thing in between.

Tacks welds to keep patch stable:

Finished welding:

Grinding welds down:

Still some beating and grinding to do to make it perfect, but for today, I am done.

Regards
Jacques

 

[Dippies]

:thumbs::thumbs: looking better already

 

[herr bmw]

raise:raise:raise:

 

[frikkieh]

Nice DIY. a Panel shop would have charged you a little fortune for that.
Now with what would you treat that to avoid it from happening again?

:thumbs:

 

[moranor@axis]

very nice work here what you going to use to seal it?

 

[Philip Foglar]

Nice DIY. a Panel shop would have charged you a little fortune for that.
Now with what would you treat that to avoid it from happening again?

:thumbs:

Yep, these days any effort seems to cost a small fortune to have done by businesses - DIY wins again!! :thumbs:

 

[Carbon]

Nice DIY. a Panel shop would have charged you a little fortune for that.
Now with what would you treat that to avoid it from happening again?

:thumbs:

And to be honest, almost all shops would do a quick patch, lap weld instead of butt weld, never grind it down and fill it with filler. A job guaranteed to rust in two years time. I don't trust shops with this, it is too easy to hide bad work. I am aiming to use almost no filler on this car, so I will go back to the hammer & dolly later this week. Even the underside should be perfect.

very nice work here what you going to use to seal it?

For now, nothing. The panel will flash rust in a couple of weeks but that is easy to get rid of. When all the patch panels are done I will do media blasting to get rid of rust, and then etch prime it right after. Then there is no chance of rust coming back.

 

[Sabretooth tiger]

Awesome work :thumbs:

 

[Carbon]

Nice DIY. a Panel shop would have charged you a little fortune for that.
Now with what would you treat that to avoid it from happening again?

:thumbs:

Yep, these days any effort seems to cost a small fortune to have done by businesses - DIY wins again!! :thumbs:

I'm not sure that shops would do this, even if you asked them. It really is a butt-load of work. I must have about 20-30 hour in that patch. But I love being able to look at my work and be proud, not to hide everything with filler.

 

[Philip Foglar]

Nice DIY. a Panel shop would have charged you a little fortune for that.
Now with what would you treat that to avoid it from happening again?

:thumbs:

Yep, these days any effort seems to cost a small fortune to have done by businesses - DIY wins again!! :thumbs:

I'm not sure that shops would do this, even if you asked them. It really is a butt-load of work. I must have about 20-30 hour in that patch. But I love being able to look at my work and be proud, not to hide everything with filler.

True! :thumbs: