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What To Do With Bare Metal Bodywork Whilst Waiting To Finish Job

rust repair

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#1 zero_wlv

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Posted 27 August 2018 - 10:46 PM

Today I was intending to strip my driver's side sill back to bare metal,  de-rust and then repaint.

I got as far as stripping to bare steel and removing some of the rust but didn't have time to go further before daylight went.

The procedure I'm using is:   BARE STEEL > DEGREASE > DEOX GEL > DEGREASE > ELECTROX > EPOXY PAINT > DYNAX

 

I've got as far as the first photo below but didn't have time to get rid of the last stubborn areas of rust in the badly pitted areas    (up until then the flapper disc and Deox had done a pretty good job of getting rid of a lot of the rust).

I've brushed the bare metal with a light coating of Dynax until I get chance to work on it again in a week's time.    The car will remain garaged till then.

 

Is this the usual way to deal with bare metal when you can't get the job completed in a day?    (Sorry for silly questions,  but I've never really done any bodywork before).

 

Attached File  1_27Aug2018.jpg   59.24K   8 downloads

 

Also,  I get the feeling that some parts of the rust in the photo might be too stubborn to get off at all.   Would it be foolishly sloppy to accept defeat and paint over them,  knowing that at least I've got the bulk of the rust off?

 

Another question:   I've been using a flapper disc+angle grinder to get most of the paint off.    Is there any risk that if I'm over-zealous with it I might thin the steel out too much?     I'd got the impression that flapper discs were only abrasive enough to remove paint but it was giving off quite a lot of sparks (presumably removing metal).     There are two small areas where tiny holes appeared by the time I finished  (like the hole in the attached pic),  although I'm not massively worried about them.

 

Attached File  2_20180827_185344.jpg   43.84K   12 downloads

 



#2 harrythehat

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Posted 28 August 2018 - 06:58 AM

Hi flappy discs will still take metal away

floor and cill looks a little quilt Like,

from what is being shown could well be tempted to cut out and replace, but cant see it all for confirmation and would be taking close looks at welding seams etc



#3 Bat

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Posted 28 August 2018 - 09:41 AM

Hi,

If you're not painting the car you'll be ok.

If you're paying to piabt the car, cut out all the rusty or dodgy looking bits and weld in new metal.

Cheers  :proud:



#4 zero_wlv

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Posted 28 August 2018 - 12:54 PM

Hi Harry,

 

What do you mean by 'quilt' like,   and could this cause a problem?



#5 dasupersprint

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Posted 28 August 2018 - 12:59 PM

To clean a surface from rust or paint I always use a wire brush wheel on a grinder

KOYlfeH.jpg


Edited by dasupersprint, 28 August 2018 - 12:59 PM.


#6 elliot341

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Posted 28 August 2018 - 02:37 PM

I think Harry is saying that the floor there looks a bit like its had a few patches on it and might benefit from a tidy up and possibly replaced with larger panels etc.



#7 sonikk4

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Posted 28 August 2018 - 06:17 PM

To be blunt and to save you further issues those sills inner and outer are toast.

 

You need to replace them. What you are doing is only going to hold back the inevitable and judging by those pictures and the serious pitting i can see it will be very quick to rust again.

 

Sorry not what you want to hear but its speaking from experience here.



#8 zero_wlv

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Posted 31 August 2018 - 12:38 PM

Thanks for the replies,  after what Sonikk advises I'll be saving up the money to have sills replaced on both sides, especially as they have been patched up quite a bit.

 

It appears to me that the state of them isn't urgent enough to pose an immediate safety risk  (someone please tell me if they disagree) so for the moment I'll Electrox and paint over the bare steel and look into getting the sills replaced early next year.

 

Also, if anyone has any advice on roughly how much the parts and labour would cost to replace the whole inner and outer sill on each side,  this would be appreciated.     I've seen on another thread that M-Machine sell combined  inner/outer sub-assemblies with jacking points and a couple of inches of floor already attached.



#9 Ethel

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Posted 31 August 2018 - 02:12 PM

Neil beat me to it. You can bet they'll be at least as bad on the inside. I wouldn't put too much time and money into the outside.

 

Give 'em a slathering of phosphoric rust converter then a coat of any waterproof paint you have to hand.



#10 harrythehat

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Posted 01 September 2018 - 07:09 AM

Quilt like to me

is yes loads of patches looks like the quilt on my bed,

cut it out and replace make it look like a freshly ironed sheet

Much nicer knowing inside is as good as out



#11 sonikk4

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Posted 01 September 2018 - 09:08 AM

Thanks for the replies,  after what Sonikk advises I'll be saving up the money to have sills replaced on both sides, especially as they have been patched up quite a bit.

 

It appears to me that the state of them isn't urgent enough to pose an immediate safety risk  (someone please tell me if they disagree) so for the moment I'll Electrox and paint over the bare steel and look into getting the sills replaced early next year.

 

Also, if anyone has any advice on roughly how much the parts and labour would cost to replace the whole inner and outer sill on each side,  this would be appreciated.     I've seen on another thread that M-Machine sell combined  inner/outer sub-assemblies with jacking points and a couple of inches of floor already attached.

 

It will not be cheap taking it to a garage or bodyshop to have the work done. It is quite an involved job as certain areas like the companion bins make access very difficult. Realistically the bins need to come out to get to the inner sill where it mounts to the stiffener inside the bin and where it picks up on the heelboard.

 

Having done these before on my car and another resto i did for a workmate i know whats involved. Sorry as for price to do the work i could not say.

 

Oh and both cars i used M Machine full inner sill to first flute. Not the combination inner and outer.



#12 weef

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Posted 07 September 2018 - 07:16 PM

Its what we in the trade call an Indian ...........apache.



#13 skoughi

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Posted 09 September 2018 - 08:40 AM

Apply a good coating of a phosphoric acid rust converter as suggested earlier, this'll keep down on surface rust from forming.







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