Rear bodyshell rust??? 2 door saloon.

[kingzdjc]

Hi guys,

I've got a 2 door saloon, and the rear windows have been letting water in, causing slight rust in the corners. This isnt a problem, as I am going to replace the seals.

However, I had noticed the water trickling down behind the rear interior sections, (where the armrests for the rear seats are), so I removed the sections, to see the metal behind.

The metal was sticky, painted in like a tar, so just wondering what this is? Also, as this metal is apart of the actual bodyshell, if this rusts, which I dont think it has, it it possible to remove a section of metal and weilding in a new piece? Baring in mind that this metal section is apart of the actual bodyshell?

Thanks


Section in question is shown in bottom picture, above rear wheel arch, and behind the front door
Daniel[frame][/frame]

[mogbob]

Daniel
The coating will have protected the section you are referring to...usually.If accident damage has occurred and was badly repaired then replacement ...of the whole panel can be done.
The more common scenario is rust around the edges of the wing seam and cill area.If you go onto ESM's website you can see
the wide range of repair panels available.
As with all welding, removal of things to get good access is the thing that takes the time and adds to the overall cost.
Treat any small areas of surface rust whilst the trim is off, replace the window seals and out it all back together again.
Come back to the forum if in doubt.
Bob

[kingzdjc]

Think what I'm going to do is remove the panels, and coat the entire metal surface behind the panel with waxoyl. I cant really see if it has started to rust, as most of the panel is covered in a thick tar like substance. I read somewhere that waxoyl kills existing rust, but even if it doesn't, it should prevent any futher rust if there is any from getting worse.

For piece of mind, I checked out the ESM website, and they do appear to have replaceable sections for the rear of the car. I didn't think this would be possible, because the section in question isn't a panel, but apart of the monocoque shell of the car?
So I guess this area can still be cut out and replaced then?

Daniel

[mogbob]

Daniel,

Yes you can cut out a section and weld in fresh metal ,if you have the skills.You will need to scape off the sound deadening/ underseal type stuff first around the area.
As with all replacement metal ,weigh up the cost of a repair panel against your time, fabricating the piece from scatch from a sheet of metal.
Whatever you do... sort out the welding first ...before putting waxoyl on.It's flamable !! If the heat from your MIG welder sets fire to it and you're not prepared with a fire extinguisher, it might be good bye car.

All the panels in a monocoque shell help the strength of the car.Just take your time and assess the situation.If the surfaces
to be replaced are flat, life is a whole lt easier.Clamping a strip of brass behind the weld, will cut down distortion and don't do it all in one straight run.Short runs and then move the torch somewhere else on the panel.Cover up your paintwork/ glass to protect from welding splatter.Is your petrol tank leak / fume free before you start welding? If you are very close to the tank you may have to consider removing the tank for safety.
Bob

[kingzdjc]

I have looked at the panel, and it has only rusted slightly, but mainly at the bottom. I dont think it would quantify any new pieces of metal being welded in!

I have two questions.

1.Waxoyl claims to kills old rust, so does this mean I can brush waxoyl on the entire panel over the existing rust? Would this prevent it from getting worse.

2. In the future, if the panel does need welding work, how is it possible to remove the waxoyl?

Thanks,

[bmcecosse]

Waxoyl is highly flammable - so beware in future. Best to treat surface rust with a 'killer' such as phosphoric acid (in many products) and then lay into it with the waxoyl......

[kingzdjc]

Waxoyl is highly flammable - so beware in future. Best to treat surface rust with a 'killer' such as phosphoric acid (in many products) and then lay into it with the waxoyl......

I always thought waxoyl killed the rust as it prevents oxygen and water, therefore killing the rust by stopping it from spreading?

[bmcecosse]

There are many different beliefs.......each to their own!