1991 Tornado Red Corrado G60 Daily / Project

[VW BUSH]

Be interesting to see how this comes out the bonded screens used by VW seem to be a real rust trap, they leave a leading corner / edge which chips easily and lets the water in
Welding in around the roof will be a real test of ye skills, far beyond what my ham fists are capable of good luck...
From what you did on the Mk3 I don't think you will have any issues with the sills

[Gti_Jamo]

Cheers mate!

I think also a previpusly poorly fitted screen has contributed to the rot here. Hopefully shouldn't be too bad to do and at least it'll be hidden by the seal. Aslong as it completely rust free and has a fresh flat base for the screen to bond to. The sill worries me a bit as it's a complicated section. Ideally i'd be looking to cut a bit out of a scrapper and weld it in flush.

[Gti_Jamo]

Cut out everything that was rotten and started to fabricate some strips of metal. Luckily the rot hasn't penetrated the lower skin of the frame so just a matter of replacing that then weld in a vertical strip and all should be good. Punched holes so i can puddle weld then grind smooth, also left small gaps between the strips so i can stitch weld then again smooth them off.



Part of the upper skin on the passenger side wasn't to clever either so replacing with another strip.

[Bandit127]

That sort of cutting welding isn't engineering. It is art.

Good job so far. 

[Gti_Jamo]

That sort of cutting welding isn't engineering. It is art.

Good job so far. 

Cheers mate, those strips of metal were part of a door skin of a mk3 golf this morning by the way lol. Art on a budget!!

[Gti_Jamo]

Not too much left to do, just delicately weld up and smooth off the gaps. I'd urge anyone with a corrado to check these areas for rust.

[Seanl]

Good work dude, it's a really common problem area due to bodged screen fitting. Mine is in for Windows out paint at the moment, and I've asked to be present when it goes back in to ensure it doesn't happen!

[Gti_Jamo]

Cheers mate. Yeah i'll be keeping a close eye on mine being fitted too. Gonna paint the window frame myself prior to it going in and then prob do the whole car over winter. It's been polishd so much in places it's through to the primer.

[Seanl]

Yeah mine was the same.  When I got it, it was in a real state.  I had to be very aggressive on the compound and pads to get a decent finish. Unfortunately it resulted in strike through on a couple of areas on the swage lines.  All worth it in the end though! 

[Gti_Jamo]

Got the frame finally finished. All solid now.







Just rattle canned it along with a coat of laquer just to seal it. Also used an etching primer along with a base primer to ensure it stays rust free. Rest of car will be properly painted soon. Laquer peel is beyond a joke.

Windscreen getting fitted on wednesday through my insurance which saves me a good few quid so all working out well so far.