Welding...

[RogerT]

Aye, once you start on panel replacement you’re in for the long haul. And life inevitably gets in the way (children/dogs/parents/jobs/other house jobs…). And one thing does lead to another. Some people have a routine of wire brushing the seams, adding vactan, and paint to keep rust at bay. It works for them.

Whereabouts in Cumbria are you? I grew up in West Cumbria…

[Wilf1988]

I might just do that round the seams for now but I reckon the holes are going to need patched sooner rather than later.
I think starting with the window surrounds sounds like a good idea, looks an easier starting point than the panels. I've sort of written off using it this year and just going to concentrate on getting the rust sorted so I can get it resprayed later on in the year. Luckily I've got three weeks off work coming up so plan to get a good bit done then...
I'm near ireby, great part of the world!

[RogerT]

Ireby looks beautiful, I grew up in Dean, and so wasn’t over that way at all. Cycling was my thing then, so round the lakes, the high passes, and over to ‘spatri’ and silloth.

[RogerT]

Good plan with the rust, tho in time you’ve got a shedload of work to do, or you’ll be left with a shed.

[Wilf1988]

Yea its nice, Dean is lovely too, and most importantly has a great pub!
Just working on somewhere to keep her and what welder to get. If I can find a decent place to keep her inside then it can take as long as I need.
I'd rather do it properly than go round in circles chasing rust!
I'll post pics as I go so you guys can keep me on the right track.

Thanks again guys!

[multisi]

It will need full panel replacements to stop the rust coming back, open up the area above the rear jacking point to get a better look of the possible structural corrosion in that area. Buy the best panels you can afford.

[Wilf1988]

Right guys, I've made a start... this is what I'm faced with so far. The arch had so much filler in it I didn't think it was going to stop but the metal underneath isn't too bad. C pillar is rotten at the sill. Since the majority of the panels are decent I'm thinking I might not need to replace the whole thing. What do you think??

[multisi]

That wheel arch and side panel need to go, the rust has got between the panels to the rear as well so a strip of the rear corner panel needs to come off and new metal with a return for joining to the side panel needs forming , that sliding door side panel is the easiest to remove, there is easy access to the spot welds at the front edge.

[RogerT]

And the base of the c pillar and top of the trailing arm mount/rear jacking point will probably have to be rebuilt. Which leads onto the sill…

[Wilf1988]

OK thanks guys, I'll order some panels. Klokkerholm tall panel seems to be the only option at the minute... they get very mixed reviews!

[Wilf1988]

So bottom of c pillar is knackered plus a hole in the sill. Have a new c pillar would it be a decent repair to square up the hole and weld a patch in? Or should I be using one of the specific repair panels?

[multisi]

Best to open up that area and see what its like above the jacking area, the lower panel with the rust hole is available 251809397A about £20.

[RogerT]

And you’ll struggle to weld anything to the c pillar without cutting away all that rust. Looks worse than mine was I’m afraid. And cutting off the rust on the c pillar means getting into the side panel. Or is that the sliding door side? I’d investigate the inner and outer sill, and look at how much is left of your rear jacking point/trailing arm mount. I ended up doing the whole lot, but I wanted to do it once and not have to revisit it. Depends on your circumstances…

[Wilf1988]

Yea thought that so I bought this...


As I say I've got a c pillar pleased I did as the rust extends quite far up.



Also wheel arch needs fettling...

[Wilf1988]

It is sliding door side... the fridge side looks even worse!!