rust our biggest enemy

[TURBO-AE86]

hi to every one in the ae86 world
decided to paint the under side of my car and wheel arches wile im waiting to get it on the road feels like it never going to happen

its farily clean so was just expecting some small surfiss rust but didnt expect to find this its that bad the boilts that hold on the qutar pannell broke off wile trying to take them off(not good) luckily the other side is not so bad

a little un sure what to do but im thinking of cutting it out both sides getting some steel weilded in to it and weilding it back on ,can any one give me advice on it ,is it a bad spot so cut out of the car ???and put back in




wow just noticed the flexi pipe has a bit of red glow wonder how bright it gets after hard driving .

[TURBO-AE86]

were would be the best place to cut

[NoHachi]

Its probably best to have a professional welder look at this and replace the entire thing (front of sills).
It has started rusting from within, so most likely there is not much usefull metal left inside the front sills. So the "having metal welded back thing" is probably a lot more difficult then rebuilding it from sheetmetal.

[TURBO-AE86]

thanks for the advice have a friend that is a metalsmith will get him to have a look at it but thinking of cutting it off me self ,how can i prevent this happing again from in side or is their now way round it because the weilding will burn off some of the paint in side ???

[Ivan141]

Drill small access holes from the top, then spray from inside with your rust inhibitor of choice. Do this on a few spots along the whole length of the sills.
Finish the holes with a bit of paint on a brush to prevent them becoming new rust spot starters (before spraying anything in offcourse). Most of the commercially available coatings come with plastic caps for closing off the holes afterwards.

Take your pick from any type of hollow space coating;
ML Tectyl
Waxoil
Mike Sanders fat (supposedly the best).
etc..

Or just use some old used oil and apply generously. If your repeat this
last one once every couple of years it is supposedly pretty good, and cheap.
Just not too nice on the environment. I do think you would need some drainage for this last method to allow the oil to exit again.

[TURBO-AE86]

thank dude thats very good idea i will do that
got some Waxoil should i just put it stright on or is their a need for a under coat if so what sorta paint should i use ,i plan to sand it all back to bare metal
thank you

[NoHachi]

TO DO:

Have a welder (dunno about metalsmith) look at car or devellop awesome skills yourself.
Have person that will do welding do the cutting of the metal (this is going to hurt).
Keep on cutting until no rust is left at all. This will take longer then you'll like or anticipate.
Stand back and notice half of the sills is missing, work to restore composure
Weld in the replacement pieces after building them.
Do a standard 2 or 3 step painting proces on the newly welded metal. Etch primer, base coat, clear coat.
Drill holes into top of sill, treat holes to primer and paint.
Inject fat/waxoil/oil into the now completely rustfree sidesill. You'll need one of those special thingies that has a spray nozzle that squirts in all directions. You will make a mess
Insert plugs into fresh holes (buy or make out of rubber or plastic)
Drill new drainage holes into bottom of sill. 2 should be enough.
Repeat waxoil step each year, fat is a little better.

[TURBO-AE86]

i say metalsmith thats just what we all call him here he is a professional mig welder tig welder and arc welder and sheet metal fabricator every one just refairs to him as that lol im going to give it a go ,at least if i f it up it will be on my head ,i done fair few months of welding and sheet fab ,when i left school so cant see it going to bad but thanks for you advice very help full ,will stick up some picks of my progess

[nægterdu]

Dont think your's bad at all.

Here how i did mine.

[TURBO-AE86]

did it take you long ,you covered it over was their no rust in side ,mine leeks when it is wet out in to the car ,but that wont happen any more i put silcone over all the joints and lots and lots of waxoil
NOHACHI you were wright about taking longer than i anticipated it took like 3 days to clean then sand and take off what ever i neaded ,just need to cut out the sill now, get rid of the rust have not done it yet cause my wielder is on vacation .




couldnt take off the fule lines cause they are rusted and didnt want to brake them so took out the fule pump and the fule tank was free .next time ill make sure the tank is empty and not thrust what it says on the dash it said it was near empty but i got 15 leaters out of it