Author Topic: how would you fix this ( bodywork rust )  (Read 1846 times)

Offline golfgtioz

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how would you fix this ( bodywork rust )
« on: 30 March 2009, 19:34 »
well ive been doing loads of welding so far on my ill fated mk2 golf gti project . it seems everything i remove uncovers yet more rusty holes . loosing the enthusiasm v fast but ive owned this golf for around 11 years so it would be a shame to scrap it , or on the other hand ive had my moneys worth so time to move on

now I'm no expert bodyworkist but i am quite handy with a welder but I'm just after a bit of advise on ways to fix the problem below ( boot lid hinge )

« Last Edit: 30 March 2009, 19:36 by golfgtioz »

Offline Diamond Hell

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Re: how would you fix this ( bodywork rust )
« Reply #1 on: 30 March 2009, 21:10 »
Find a good one, cut that one out and stitch in the good one.

Tough repair though.
Just because you're offended doesn't make you right.

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Offline golfgtioz

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Re: how would you fix this ( bodywork rust )
« Reply #2 on: 30 March 2009, 21:34 »
thats what i was thinking myself .. "now thats going to be a right f++ker to fix", to be honest ive even found a couple of even harder technical plates that need doing around the rear axle mounts that I'm trying to blank out of my mind for now .. well after 11 years of wonderful ownership i feel my old flog has finally gone beyond the point of economical repair considering the price you can buy them for these days .. tis a sad sad day ..

Offline skem55

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Re: how would you fix this ( bodywork rust )
« Reply #3 on: 30 March 2009, 23:37 »
well ive been doing loads of welding so far on my ill fated mk2 golf gti project . it seems everything i remove uncovers yet more rusty holes . loosing the enthusiasm v fast but ive owned this golf for around 11 years so it would be a shame to scrap it , or on the other hand ive had my moneys worth so time to move on

now I'm no expert bodyworkist but i am quite handy with a welder but I'm just after a bit of advise on ways to fix the problem below ( boot lid hinge )


if your quite handy with a welder, id be inclined to cut the section and replace with section from donor at the end of the day, it aint that big as job if u have the time n patience

stuart

Offline Thom89

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Re: how would you fix this ( bodywork rust )
« Reply #4 on: 31 March 2009, 01:37 »
Forget cutting a piece from a donor car, thats like doing the job twice.. In this case, shape is not critical, as long as the holes are in the correct position, and the hinge surface area is at the correct angle, duplicate whats already there, by cutting a plate slightly larger than the rusted area, form the "squared edges" with a vice and/or molegrips, lay your new patch over the top of the rusted area, hold in position, and scribe the mounting holes from underneath, remove, and drill holes in the new plate, now bolt your new plate into position, scribe the outer edge, remove plate, and carefully cut out rusted area, up to the scribe line, remove paint ready for welding, refit the plate, and bolt into place.. tack weld plate into position, and recheck that the tailgate still fits... fully weld into place, dress with a grinder, fill as required, go to pub etc etc
Tom

Offline Simeon

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Re: how would you fix this ( bodywork rust )
« Reply #5 on: 31 March 2009, 23:58 »
If the metal around those holes is good then you can just fill them with weld if you're handy with the welder. If you can get behind then you can use a block of copper to make the job easier. 

Offline scotty iom

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Re: how would you fix this ( bodywork rust )
« Reply #6 on: 01 April 2009, 00:53 »
Yep, fill them in with weld,  dont have the welder to hot and turn your wire speed down a tad..
dont need to be a good welder .... just be good with the grinder .. 

Offline Simeon

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Re: how would you fix this ( bodywork rust )
« Reply #7 on: 01 April 2009, 02:03 »
dont need to be a good welder .... just be good with the grinder .. 

:grin: Fair comment

Offline Ben Lessani

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Re: how would you fix this ( bodywork rust )
« Reply #8 on: 03 April 2009, 20:35 »
You'll find yourself chasing the hole for a while if you try to fill it with weld. If its holed, then the metal is going to be pretty thin so its just going to disappear when you get the welder on there.

I'd just cut it out, weld a new plate in with recessed lips on either side, push it in from behind, spot weld the lips into the existing panel, then seam weld the main section.

Offline golfgtioz

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Re: how would you fix this ( bodywork rust )
« Reply #9 on: 05 April 2009, 23:32 »
all sorted now .. cheers for the help chaps .. went for the cut as much tin worm out a possible and fit a plate technique . just need to fix the hole on the near the rear axle hanger , repair / replace the near side sill , fix hole in rear panel , wire in the fly by wire for the tdi , remake all the brake lines , rebuild the vr6 brakes , refit all interior , buy some new coilovers , ect ect ect ect ect .. and ive just put an offer in for a new house which will hopefully be accepted monday  .. oh bugger

jobs done so far , replaced battery tray and opposite air filter panel, replace scuttle panel , replace both wings , repair boot lid hinge , repair full filler and inner wing + strut top ,replace  both doors , tailgate , bonnet ,sunroof panel , flush and paint engine bay in nice met black ..