Dimma Rust Problems

[Ric Handley 0]

After picking up my new standard lights for the Dimma (thanks Ed!) I decided to try and fit them. Something which was meant to be a simple job has turned into a nightmare!

 

There are 2 big problems.

 

Problem 1 being the dreaded rust. The previous owner told me the whole front end had been changed, what he failed to mention was that the poor quality of finish !

 

After removing the morrettes and bumper (snapping both the rectangular front bumper boltsdoes anyone know the part number please?) I discovered surface rust where the paint (1 thin coat) had flaked off.

 

 

After further investigation (with a wire bush) I sadly found the extent of the surface rust. The paint is so thin that it looks like the whole front panel is affected.

 

 

After a quick once over with a wire brush attachment on a drill it seemed to come up ok with only rust pitting along the edges.

 

 

Whats the best way to treat this? I was thinking of sanding down the pitting as much as I can (whats the best method/equipment please?) then kurerust, then zinc priming, then top coat.

 

It is annoying that someone has spent a lot of time fitting this new panel and then spraying straight onto it with a thin layer of top coat nothing else! (and it looks like it was damp when they did it too )

 

Problem 2.

 

The standard lights wont actually fit (so I have uncovered hours of rust work.for nothing *sigh*). The problem is the indicators have no metal to fix screw in to (neither top nor bottom screws).

 

 

How do I get round this one!?? Has anyone else had to deal with this problem?

 

Anyone want to buy a Dimma?

 

Thanks for reading and please help me!

 

Ric

Edited May 8, 2007 by Ric Handley

[Grim.Badger 15]

That's not where the indicator bolts on It's hard to explain but it has a large screw on its side; the body should slide into a metal "case" which looks missing on yours, and then this big screw bolts them together. It's the same big screw that holds the spring clip iirc

 

It has been a while since I've done this though so my info could be a bit confused

[matty_gti 20]

That's not where the indicator bolts on It's hard to explain but it has a large screw on its side; the body should slide into a metal "case" which looks missing on yours, and then this big screw bolts them together. It's the same big screw that holds the spring clip iirc

 

It has been a while since I've done this though so my info could be a bit confused

 

Like Grim.Badger said really, the indicator is held in by its own screw. The bolt that is mising on yours holds the black headlight adjuster to the body, and then the indicator screw to that.

 

If you look on the side of the indicator there are allmost like 'rails' and a whole in the middle for a screw. When the indicator slides into its space, the rails will line up with the headlight adjuster and then you secure it with the screw.

 

Hope this helps.....

 

http://i81.photobucket.com/albums/j218/mat...ti/DSC00403.jpg

 

Is there any way of drilling a new whole in the adjuster securing it to the body?

Edited May 11, 2007 by cybernck

[Jrod 7]

Looks like its been cut where the little slider thing fits, Maybe weld on a small plate then drill hole?

 

Could be akward come mot time for headlight aim.

[Rob_the_Sparky 9]

As for rust I think you have the right idea. Grind back everything to bare metal (and I mean everything, not just the obvious bits), phosphate it, primer and topcost (a few coats of each).

 

If feeling particularly paranoid then a layer of waxoyl over the top will not look pretty but will also help.

 

Key thing is to get it back to bare metal though, leave any rust and it will come back through (then waxoyl is a pain in the bum!).

 

Rob

[gti-si 0]

Looks like Jrod has the right idea, I think your best bet is to cut and weld a plate and then mount it on that. Wonder why the original plate was cut off, is it a necessity for fitting the Dimma kit?

 

edit: just realised it'll of been cut for the twin headlight jobbies...i think?

Edited May 9, 2007 by gti-si

[Ric Handley 0]

That's not where the indicator bolts on It's hard to explain but it has a large screw on its side; the body should slide into a metal "case" which looks missing on yours, and then this big screw bolts them together. It's the same big screw that holds the spring clip iirc

 

It has been a while since I've done this though so my info could be a bit confused

 

Sorry i didnt explain this well....i know the indicator fixes to the headlight adjuster unit...but then that has to fix to the body but there is no metal there.

 

 

Is there any way of drilling a new whole in the adjuster securing it to the body?

 

I'm not sure if this is an option yet, I dont think the angles are right to screw it to anywhere else. I'll have to study it further.

 

Looks like Jrod has the right idea, I think your best bet is to cut and weld a plate and then mount it on that. Wonder why the original plate was cut off, is it a necessity for fitting the Dimma kit?

 

edit: just realised it'll of been cut for the twin headlight jobbies...i think?

 

It has a whole new front panel which i would assume isnt a genuine peugeot one. It doesnt look like someone has cut the panel to fit the morrettes, its too clean a cut.

 

I luckily have a mates dad who is good with a welder, hopefully he will be able to weld a plate to a good standard.

 

Its annoying that this has put back the 'on the road' date. I was hoping to get it sorted for summer driving.

[Ric Handley 0]

As for rust I think you have the right idea. Grind back everything to bare metal (and I mean everything, not just the obvious bits), phosphate it, primer and topcost (a few coats of each).

 

If feeling particularly paranoid then a layer of waxoyl over the top will not look pretty but will also help.

 

Key thing is to get it back to bare metal though, leave any rust and it will come back through (then waxoyl is a pain in the bum!).

 

Rob

 

phosphate it? Where do i get this from and how is it applied please?

 

Im not too fused about the looks as it will be hidden, so i think apply everything I can to prevent it again (waxoyl)

 

Thank you all for your replies!

 

Ric

[Rob_the_Sparky 9]

Check the stuff you are using, most contains phosphoric acid. This reacts to create a layer of phosphate on the metal. My personal preference is Trustron but Kurerust may well also contain it. A quick look at the bottle will tell you.

 

Rob

[Hilgie 16 2 Cars]

I don't know which kind of twin headlights had been fitted, but when I fitted my Optilux headlights I need to cut away the exact same piece of metal. So now I cannot fit standard headlights and blinkers back either. Look like new fron panel time!!! Or maybe a cheap solution might be to cut those parts from a base model at the scrappy and have that welded in before spraying.

[Ric Handley 0]

Check the stuff you are using, most contains phosphoric acid. This reacts to create a layer of phosphate on the metal. My personal preference is Trustron but Kurerust may well also contain it. A quick look at the bottle will tell you.

 

Rob

 

Thanks Rob, I'll have a look at the stuff I'm going to buy and make sure it has phosphoric acid in it Hopefully it will keep the rust away for a few years.

 

I don't know which kind of twin headlights had been fitted, but when I fitted my Optilux headlights I need to cut away the exact same piece of metal. So now I cannot fit standard headlights and blinkers back either. Look like new fron panel time!!! Or maybe a cheap solution might be to cut those parts from a base model at the scrappy and have that welded in before spraying.

 

I'm not liking the idea of a new front panel!!

 

I think the best solution is to weld on a new bit of metal (good idea about using metal from a scrap base model!)

 

I will try and keep this thread up to date with progress and which solutions I went with in the end.

 

Thanks for all the advice

 

Ric