Anyone Experienced With Serious Rust Removal

[ke70km/h]

I was just wondering how you guys handled rust in your corollas lol since we're all driving vintage machines. The boot in my ke70 is almost rusted through and spots around my petrol cap too.

 

I'm thinking of taking up oxy acetylene welding. Maybe cut out the rust find a piece from a donor car and welding back into the hole. I don't want a crappy bog job lol because my ke70 deserves the best.

[Medicine_Man]

I have another brown KE70 in the backyard that has the same problem with the tyre well. I got a cut out of another KE70 to weld in later when I eventually get to it..

[love ke70]

this is becoming one of those "I'm not going to search, coz I'm sure no one has posted about it before" topics

http://s29.photobucket.com/albums/c292/arowland2/rust/

before i started

http://s29.photobucket.com/albums/c292/aro...rust%20repairs/

after i finished

 

what you do:

1: get angle grinder, grind away all patches of rust and cut out the holy sections (sunday sections) :S

2: get a sheet of decent but not too thick steel. a few different thicknesses depending on the job helps. (in the rear window corners i used 3mm galv steel. other sections 1.5 mm galv steel and others computer or other white good cases.

3: cut steel to approximate shape (i used a bandsaw) and then bash with a hammer to resemble the shape it should, either clamp or rivet in place. (i always clamped mine)

4) weld it in

5) grind it back so nothing sits above the level it should (hammers are helpful)

6) treat it with an anti rusting substance ( i used a product called penetrol, its great, been almost 18 months, nothing has come back that i treated with the stuff)

7) bog bog bog til your hearts content

8) sand sand sand til there is no skin left on your fingers

9) repeat steps 7 and 8 for many months

10) it must be right now, prob gettin close

11) now its time to sand the whole car back (orbital sander ftw)

12) primer, and sand, primer and contrast coat and sand, primer and contrast coat and sand, primer and contrast coat and sand, primer and contrast coat and sand (ALWAYS sand using a block at this stage, so that you remove all the valleys and peaks that appear in old metal) the contrast coat shows you the low and high spots (for the contrast i used a tin of red export spray paint) p.s if youve gone to the effort of doing a good job with the rust repairs don't f@$k out on the making it straight stage. as tedious and irritating as it is :D

13) many months later you will have a car that is straight

14) now spray it and clear it and sand and polish

15) go for a spin and try not to crash into a pole :S

 

hmm i think thats the basics

any questions?

 

oh, for the record, i did not use any panels off other cars

even the spare tyre well i welded plates into and bogged up (its so f@$kin shit in there tho, tyre sits about a cm taller than it should. maybe it would be a good idea if your tyre well is rusted out to get a replacement one. i have a rust free one if you need.. but as you havnt PUT YOUR LOCATION IN YOUR PROFILE i can't tell whether its any good to you ;)

 

hope ive helped

 

anyone, feel free to correct me

[7shades]

Chook mesh and fibreglass old sausage...

[love ke70]

he said no dodgy spec styles :D

[7shades]

He only said no bog... :D

 

But in all seriousness I had an RA40 celica with the same problem. I just picked up a sheet of 1mm steel and made a completely new spare wheel well. Not a hard job at all, just a jigsaw with a fine metal blade and a few tack welds. Once the tub was tacked into place I just ran around the gaps with a line of sikaflex.

[anastasios]

hehe ive just dropped the ae71 into the panel beaters today! found these guys who are cheap and willing to weld metal in