Rob Thomson 6 Posted February 24, 2008 I've recently been giving my nice little 1992 1.6 GTi a rebuild. I was originally a bit concerned about the state of the bodywork, but when I took the engine out I had a poke around and everything seemed ok - just a load of surrface rust that even I could sort out... So I cracked on getting the mechanicals and electrics sorted out. Now, with the finish line vaguely in sight, I thought it was time to sort out that surface rust and attacked all the loose paint with various drill attachments and wire brushes. The driver's side - which appeared by far the worst - is fine and cleaned up nicely. The passenger's side - which to all the world seemed perfect bar one or two little bubbles of surface rust - now looks like this... Close-up... And underneath... Bugger. At first I thought the damage was limited to the holes, but after a bit more poking around pretty much the whole seam dropped off. Bugger. I've got enough new parts to build a new 205 sitting in the spare room downstairs. I've got a rebuilt gearbox and an almost rebuilt engine sitting in the garage. Anthony's rebuilding my rear beam. Everything is just about ready to be bolted to the shell, but now I find that the shell's f***ed... I've got to move house in a month or so, so either I fix this quickly or throw the lot in the nearest hedge. Bugger. Anyone got any cunning plans? PS. I can't weld. Share this post Link to post Share on other sites
swordfish210 20 Posted February 24, 2008 pfffff thats nothing, the shells fine, you should see the Sierra that we've got at college. It's got about a million and one holes in it and it's being rebuilt as a rally car. If you can't wels then i suggest that you find someone who can and use a plasma cutter to cut out all of the rusty metal, make a replica plate out of appropriate size steel and have it welded in place. Either that or just paint over it and pretend it's not there Share this post Link to post Share on other sites
Rob Thomson 6 Posted February 24, 2008 I think what I'm really after is how to do a bodge that'll work for a years or so until I've got more time/money/space to sort it out properly. You're right, compared to old Fords this is immaculate!! Share this post Link to post Share on other sites
welshpug 1,657 Posted February 24, 2008 I think Tom Fenton or Paintguy would be the ones to ask on this one Share this post Link to post Share on other sites
jonnie205 1 Posted February 24, 2008 thats barely enough to worry about, hardly worth cutting out holes prob best just to mig the holes up then grind flush, etch prime then top coat Share this post Link to post Share on other sites
newdean0 0 Posted February 24, 2008 That should be quite easy but it will involve some welding if you want it to last. I don't think that's a critical part of the shell so you could feasibly do all the prep i.e. cut the old metal out and create a new repair section from sheet metal then drive the car to a local garage to get it welded. I'd cut along the inner wing (on the horizontal part) a strip about 1cm wide (basically back to solid metal). An angle grinder with a thin cutting disc would do that job easily. Then use a cold chisel to break apart the rusty old seam. You then need to clean the remaining side of the seam until it's nice and shiney. An angle grinder with wire brush attachement will do that nicely, doing it by hand is hard work. The most important part is to make sure any rust is cut out, it's much harder to weld to rusty metal; the weld won't last long and will be much weaker. Once it's shiney give it a coat of weld through primer. You'll then need to cut an L shaped bit of steel (I used 0.8mm) and get it welded in place. Shouldn't take more than 3 hours or so for the prep. Share this post Link to post Share on other sites
brianthemagical 1 Posted February 24, 2008 It's really hard to get a grinder in near the front of that section, not sure what it's like with the wing off. Within 30cm i think it is of criticle mounting points, i.e. sus, needs to be structurally sound. Share this post Link to post Share on other sites
Rob Thomson 6 Posted February 24, 2008 Thanks for all the replies. I should have thought about this a bit more before I posted... Once the car's up and running I'm planning to take it to a decent local bodyshop to have a couple of small dents sorted out and a new door fitted and sprayed. I'm more than happy to pay for this damage to be repaired professionally at the same time... but I need it to pass an MOT first. I could get one of my mates to come round and attack it with his MIG, but although it would probably be ok structurally it would be a mess and I want(ed) this car to last. I'm vaguely tempted to fibreglass, fill and paint as a temporary bodge to get it through the MOT. Anyone see any great problem with that? Share this post Link to post Share on other sites
welshpug 1,657 Posted February 24, 2008 should be fine Rob, what they don't see they wont poke, my 205 has a hole at the front end of that panel where it meets the headlamp panel, it only this year got to an advisory level and I can stick my finger through it I think I'll be welding it next year... Share this post Link to post Share on other sites
Jrod 7 Posted February 24, 2008 I had a hole in an old xs, just cleaned it up and tigersealed a piece of alloy over it then covered it in more sealant. Share this post Link to post Share on other sites
AdamVester 0 Posted February 24, 2008 sand it, treat it filler over the top and some anti-rust paint around that... done Share this post Link to post Share on other sites
Tom Fenton 1,542 Posted February 24, 2008 I can think of two options, the bodge way and the proper repair way. For the proper repair way see the first page of the following thread- http://forum.205gtidrivers.com/index.php?s...c=83788&hl= For the bodge way get a 20/25mm holesaw and drill a circular hole straight through the rotten bit so as it looks like it is supposed to be there, fill it with a grommet. Share this post Link to post Share on other sites
