Club 80-90 Forums

Hello all, could any one offer any advice on how to repair this? I plan on cutting the rot out but unsure on how to go about welding new metal in. Its a very awkward job by the looks of it, the rust goes around the corner of the window.
would it be possible to weld in new metal to bridge the space thats been cut out and then weld a lip to it to hold the seal? Or must it be done the same as the existing metal work that holds the seal?
Many thanks,
Rob.

Keep an eye on those little rust spots around your windows or you could end up with this! I really dont know how folk can let a van just rot away for the sake a little work.

More pics from each side would help to see how bad the rot is.
Would suggest cleaning up the rust first and highlighting with a marker pen the bad areas.

Finnicky to repair but not difficult, the opening once repaired needs to be a few mm larger than the glass to allow for the seal. Corners you can cut with a jigsaw.

Hi Wookster, thanks. I will try and get some more fotos up soon, its good to hear its a repairable job i thought i could be looking at a transplant tailgate. Because the rot in the foto is so bad rain has been litterally belting through the hole right down into the bottom crevice of the door causing yet more rust, that looks like a hell of an awkward place to get at. Great tip regarding the jigsaw.
Thanks again.

Damn Rob, that does look bad, and I guess I won't know if mine is as bad until I remove the windows, but upon cleaning up some rust spots, I have indeed found holed areas under the rubber seals

its do-able but you would be lucky to get it right and retain the internal and external visible profiles, could easy end up looking rough, be quicker/easier to pop another one on,
mm

Its rough Mickyfin, i knew i was in for a shock before i removed the window, thanks metalmicky, thats what i was thinking it definatly wont be easy to repair this, welding thin metal in and trying to match the existing profile is gonna tough, maybe i say i'll source another tailgate but in the mean time try and repair it ya never know!
Its definatly worth sorting those small rust spots or it could lead to this, i sotred the other windows they were nothing like as bad as this one just a couple of little spots and paint blisters.
Thanks.

That looks pretty bad....didn't know they rusted at the rear screen as well as the front. Luckily mine is mint under the rear seal. I wouldn't even try to repair that, go for a replacement tailgate. If you grit blasted that, you'd have lots and lots of holes.

THanks folks, if i grit blasted it i dont think there'd be a door left, will have to have a search for a 'new' one. Thanks again.