Need To Fix Rust

[lil_mike]

hi guys,

 

i have to fix some rust on my '79 KE55 corolla (wow, shock horror!). Was wondering if anyone who has done this before could give me a hand. First time i've had to fix rust and a little unsure of how to do some things (eg: welding) Of course there will be renumeration for anyone who can help.

 

its mostly on the rear quarter panel, passenger door sill and a few very minor spots here and there. most of the minor spots are just surface rust though and could be removed easily.

 

I did have a friend who was going to help me with this but he can't do it anymore, so i'm seeing if anyone in brisbane can give me a hand.

 

So if anyone can give me a hand let me know.

 

thanks,

 

Mike

[tas_ae71]

what sort of tools have you got..? spray gun, compressor, welder/grinder etc..?

 

in most cases i vote to fix rust holes by cutting and welding new metal in. if you don't have a welder and welding skills it maybe a better option to clean up all the rust and treat it then use fiberglass. its really upto you, metal will last longer.

[Clapped out]

hi there mate, any chance of some pics of the rust? just so that we can give you better advice, and yes (great suggestion tas ae71), let us know exactly what tools you have at your disposal to use,

 

cheers phatke30!

[superbmobile]

definatly cut and weld otherwise itll just come back. find someone with a welder if possible.

[lil_mike]

well, i have found a mate who can weld for me but he's never done this before either. i will hopefully be able to borrow my other friends grinder and maybe orbital sander. not going to paint it myself, leaving that to someone more skilled. i know i will have to bog it up though, but thats not incredibly hard.

 

worst of the rust is here

 

the drivers side sill is not as bad as this, but runs along the same sort of area. also, any idea on what sort of sheet metal to use?

[78_7kRolla]

I'd hate to tell you but that is a little more than just surface rust. You should let somebody more skilled tackle that section as it definately isn't for the faint hearted.

[KE30_KE35_KE55]

Easy just fabricate 2 new patchs or cut out of another car the shape shown in Picture. simply cut out as marked and weld patchs in place. seal the rear with hydro seal and its as good as new.

[lil_mike]

I'd hate to tell you but that is a little more than just surface rust. You should let somebody more skilled tackle that section as it definately isn't for the faint hearted.

never said it was just surface rust? i said the minor parts are, thats all.

 

thanks KE30, thats what i thought had to be done. my friend helping me is pretty skilled with metal, i think he's a boilermaker, and i may be able to bribe someone else into assisting :)

Edited November 14, 2007 by lil_mike

[styler]

with heavy rust you can fix it properly or fix it cheaply, the bottom of the rear quarters are a common and difficult rust area to fix.

also finding a matching section is difficult as they are all very prone to rust there :) but not impossible if you have plenty of time at a

few wreckers looking around and get them to cut it out for you far away from where you need. hard to fabricate if you don't have a good idea

of what you want and the skills / equipment to do it.

 

then the cutting and welding can be anywhere from jagged edged bird shite arc weld bog tacular slap up to a neat cut tacked mig stiched and

ground down proper repair job. depends on what equipment / skills / time / money you have. and whats worth doing for the car is another

question you should ask yourself. then you have to paint the repair too.

[Rollaboy2608]

all solid points styler. Anyone can weld in just about any old piece of metal to fix rust, but to make it look like its never been repaired is for people with a fair amount of skill

[KE30_KE35_KE55]

Here is a pic of a running board I repaired a few years ago, the diamond pattern was worn thru rusted out so i replace a whole section, I am Not a panel Beater or welder. practice makes perfect. give it a go.

 

get your self a off cut piece of new 0.8 mm flat steel sheet and have a practice first on a old panel.

Edited November 14, 2007 by KE30_KE35_KE55

[machg]

Here is a pic of a running board I repaired a few years ago, the diamond pattern was worn thru rusted out so i replace a whole section, I am Not a panel Beater or welder. practice makes perfect. give it a go.

 

get your self a off cut piece of new 0.8 mm flat steel sheet and have a practice first on a old panel.

 

I have got a huge resto project coming. Your repair looks pretty good to me, what did you use? Oxy? MIG? (With Gas or gasless wire?)

[KE30_KE35_KE55]

I have got a huge resto project coming. Your repair looks pretty good to me, what did you use? Oxy? MIG? (With Gas or gasless wire?)

 

I have a big old 3 Phase MIG with a choke fitted it gives a lot more control than modern machines. The hard part is making the patch anyone can weld and grind ect. I use a combination of sheet metal tools like a jenny wheel pictured to recess patches so they fit behind but flush at the front. spot weld and check 10 times before the final weld.

 

Butt welding is harder I used a replacement panel to repair my radiator surround pictured.

PM me if you want to see some more of My body building pictures.

[machg]

So the patch is larger than the hole, and you use the recessing so the recessed area is close in shape to the hole, you tack the patch in then run a seam weld in the gap between the recessed area on the patch and the edge of the hole?

Edited November 17, 2007 by machg

[KE30_KE35_KE55]

So the patch is larger than the hole, and you use the recessing so the recessed area is close in shape to the hole, you tack the patch in then run a seam weld in the gap between the recessed area on the patch and the edge of the hole?

 

Yes thats what I did with the running board,

With the rear quarter bottom pictured above i would use the recess on the top bend the 20mm around into the wheel arch curve the bottom then 2 sharp bends in a folder and overlap like a door skin. then at the bottom and weld at the back so it looks as the original panel.

Edited November 17, 2007 by KE30_KE35_KE55