Ol' Rusty - FB/EK Sedan

[Blacky]

Kudos to the young bloke , good to see he perseveres with a job like that instead of wandering off

[funkyscooter]

repair 1.JPG (604.23 KiB) Viewed 662 times

Found a bit of rust passenger side sill in the rear wheel arch. Previously repaired. Cut/ground out the old patch


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[funkyscooter]

repair2.JPG (833.2 KiB) Viewed 661 times

Made up a template with a bit of aluminum. Decided to have a crack at mig welding. Figured no one will ever see this.


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[ardiesse]

I've got a paper template for this section - I can photocopy it and mail it to you.

(Only just saw your aluminium one. Offer still stands.)

Rob

[funkyscooter]

repair25.JPG (796.65 KiB) Viewed 661 times

After a couple rounds of weld/ grind with gasless 8mm wire. Couple of blow throughs in both the sill and my patch. Not easy working in this space and getting the MIG torch in all the right places.


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[funkyscooter]

Thanks for the offer Rob. Still on a bit of a trip down memory lane with pictures. But want to document chronologically.


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[funkyscooter]

repair3.JPG (771.76 KiB) Viewed 658 times

A few more rounds of weld/grind (after stepping away for a week). Dremmel has been my friend in here.


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[funkyscooter]

repair4.JPG (482.71 KiB) Viewed 657 times

Finally hit it with some primer. Will leave for now and tackle the other side.


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[funkyscooter]

Okay. So not as simple as the passenger side. Noticed a few bubbles in the sill but when I attacked it with my sharpened screw driver it pretty much fell apart. Went to work with the angle grinder to check the inner sill. Looked ok under the car.


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[Errol62]

Very tidy. Yes it is a tricky spot. Do yourself a favour and get some gas.


FB ute fixer upper, EK van on rotisserie

[funkyscooter]

Not so great. Lots of little pin holes. Sigh. Did some reading and the outer sill ‘seems’ relatively simple to repair.


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[Errol62]

The paint was all that was holding the shape. Usually passenger side is worse.


FB ute fixer upper, EK van on rotisserie

[funkyscooter]

Then I got to the A pillar. Both inner and outer A pillar sections need work, as well as the subframe bracket. There is also a bit of rust in the floor around the A pillar that has been badly patch over.


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[Errol62]

It is a big job but the replacement panels help. Inner can possibly be saved? Patch from the inside and paint and protect well.


FB ute fixer upper, EK van on rotisserie

[funkyscooter]

Sill.JPG (661.25 KiB) Viewed 712 times

After much hand wringing and read decided to fix this myself. Read somewhere on this forum with regards to welding and body work that it’s only metal, if you make a mistake, cut it out and do it again. Good advice
Ordered new inner and outer sill, inner and outer A pillar section , lower fender repair section, 6mm MIG wire, a regulator, and a D bottle of gas. In for a penny.......


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