Repairing bodywork without filler

Post by **davidpidge** » Fri May 15, 2009 6:51 pm

I have some nice rust in the usual spots, (round wheel arches etc) and was wonderin if there's a way to repair strips of rust without using filler. What's the best way?

Post by **PSL184** » Fri May 15, 2009 7:04 pm

You'll never repair a panel without a filler material of some sort - either plastic filler of lead loading. The best way is to cut out the rot, weld in new metal as accurately as possible and then use a very fine skim of filler to blend in the repairs. This way they will last and not be a quick botch job.

Post by **damian1978** » Sat May 16, 2009 2:09 am

PSL184 is right - once you've welded a patch in as accurately as possible, filler is the best way to go. If done properly (applied to sound metal and not rust) it will last as long as the rest of the panel. The other option is lead loading - which is a skill in itself. I've never tried it personally, as filler is cheaper, easier and gives a top finish.

Other than that, if you're master welder you might be able to weld the panel up so well, that once it's ground down it's 'invisble'. I've seen this done on these american hotrod programmes, but it's beyond most of us DIYers (certainly me anyway, with my cheapy £78 mig welder!)

Post by **purplebargeken** » Wed May 20, 2009 1:00 pm

Lead loading is great and not so hard to do. You can buy a starter kit from Frosts for about £30 IIRC. I was shown how to do it at the local college vehicle restoration course. I used my Dolomite bootlid as a practice panel and it came out beautifully. Only word of caution is with regards to sanding the lead down, but as long as you take precautions you will be fine I'm sure. Try it, it's really interesting to do.

Good luck either way.

Ken

Post by **aupickup** » Wed May 20, 2009 8:35 pm

originally lead loading was used in various places on the vans, pick ups, saloons , trav and convertables

Post by **jaekl** » Wed May 20, 2009 9:44 pm

aupickup wrote:originally lead loading was used in various places on the vans, pick ups, saloons , trav and convertables

Such as the joint on the front wings along side the headlight. I see later cars don't have this leaded as well as new wings. Does anybody know when and why it was decided not to hide this joint? It just looks odd to me.

Post by **damian1978** » Wed May 20, 2009 9:50 pm

Good point - I've always thought that join looks odd. On the pattern panels it can be a pretty ugly looking joint.

Post by **aupickup** » Wed May 20, 2009 10:16 pm

my 69 saloon originally did not have these jonts filled in
i opted not to as well and personally i prefer it that way

the early cars had this joint filled in

also the join at the side where the side of the car and rear outer panel was also leaded also the front part of a vans roof was as well