Club 80-90 Forums

Hello all,
I've got a couple of rust issues. I've read lots of the posts about rust and window rubbers but there is a lack of pictures so I thought I would share mine.

My T25 is a panel conversion whcih I have heard is the worst combination for rust problems and windows etc.

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... e033-1.jpg[/img]

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age041.jpg[/img]

I have issues with rust build up underneath nearly all windows especially the middle sides. Some of the rubbers need replacing as they have hardened.

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age037.jpg[/img]

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age039.jpg[/img]

I have set to the rust with wire brush and wire brush/drill. Most of it is coming off but it's leaving a very bumpy surface, I'm about to wet and dry it to smooth it but in lots of places the metal is extremely thin and has gone through.

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age035.jpg[/img]

I can't really afford to get it cut and re-welded. I've seen a wire mesh in halfords that you use with filler to cover such holes but not sure if it is suitable for such jobs.

The front of my van is another story. As you can see!!!

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age024.jpg[/img]

[IMG:800:600]http://i64.photobucket.com/albums/h165/ ... age030.jpg[/img]

It is not structural but would fail its MOT (apparently if a little child walked past and stuck their fingers in they might fall off!!!) Again cutting out and welding is a costly affair, If I cut out the worst and then meshed and filled do you think it would suitable?

The pics aren't the best due to phone and poor light but any advice would be great.......Hammerite No 1 Rust Beater and Waxoyl all round I think!

Cheers
Ben

As your not looking at welding some chemical metal around the window sills should alow enough strength for you to build/sand and then hold the windoe rubber.

As for the front - my van is in exactly the same state although I have resorted to chopping the whole lower section out and fabricating a new'un! I would say that meshing it and filling/spraying would work (I found this kind of repair on my van prior to chopping it all out!) - just make sure to KRust/Jenolite the chassis member so the rotting doesn't carry on once you have repairs the area

save up and do it properly or get it done properly,dont cut corners as it will come back and bite your a***, unless your looking at off loading it.... then go the bodge it route .... why cant i say a*** "feck" it

This is what you need to do.

http://www.youtube.com/watch?v=h6eQ8CfrKkE

Simon

Thanks for replies.......

I've plled windows out today and wire brushed the rust off and taken paint/undercoat off.......It's not as bad as it looks on the photos above, I will post some tomorrow.

The front of the van is still the same but if the weather fairs I'm gonna take an angle grinder to it!!!!

Wish me luck

This is what you need to do.

http://www.youtube.com/watch?v=h6eQ8CfrKkE

Simon

been there and done it already!

syncrosimon wrote:This is what you need to do.

http://www.youtube.com/watch?v=h6eQ8CfrKkE

Simon

I can't see why the original panel wasn't cut out using a small disc cutter so as to limit colateral damage. Just a thought.
Ken

I can't see why the original panel wasn't cut out using a small disc cutter so as to limit colateral damage. Just a thought.

The dude is either using the only tools available or he is not a professional body repairer/sheet metalworker - (I mean no offence toward the guy doing the work!)

I presonaly use a plasma cutter but the reason he was using a hammer and chisel was because an angle grinder wont get in there due to the deformation pannel .
ps dont cut any thing off before you make shuer a replacment is availible .

Plasma cutter!?! Is that like a light saber....? You are right about the angle grinder/space issue there isno way it will fit in......hmmm can anyone give me an idea of how much it would cost to cut out the small strip (not the whole panel like in that YouTube film) and get another strip welded in, no painting etc....I just don't want to get ripped off!!
Ben

cheep and nasty, but if you clean it up the best you can and get a strip of metal to cover it over.
you can just bond it to the front using bonding selant and then fill over the lot.
i would under seal inside realy well .