Areas that rust - Window frames

Intro

Pepperami: OK here goes.

A step by step guide on how to repair rusty windows. I know this has already been done but i will attempt to give more detail and any tips i can think of. I will also use the Queens English.

The problem

The rubber window seals go hard and shrink this allows water to enter under them which rusts the window surrounds. Another knock on effect of this is water gets into the panels rusting the seams from the inside, check behind your interior panels to see how bad it is.

Photo-article

Pictures of the rust before repair

I took these pictures quite a while ago. The o/s window had to be repaired in an emergency when I blew a hole in it using a power washer.

Step 1 Removing the windows

Using a screw driver pull out the rubber strips.

Then using a Stanley knife cut the seal around the window and then you should then be able just take the window out. Doing it this way is a one man job

Step 2. Stand back and assess how bad the rust is

At this point it may not appear too bad!!!!

Step 3 The clean up

I tried a wire brush on a drill for this as i didn't want to be too aggressive with it but had to resort to using a knotted wire brush on my angle grinder. clean up beyond the rust as you will need clean metal later to weld to.

H&S Wear PPE. A minimum of goggles and rigger gloves. A full face mask is a good idea as red-hot flying rust and wire hurts and can scar the face.

Top tip Buy goggles with yellow lenses as this brightens thing up if light isn't great.

Disconnect the batteries, remove the gas bottles and anything that is combustable. Keep a fire extinguisher handy and another top tip keep spray bottle of water handy as this is less messy for dousing those little smoulders.

Step 4 Cutting the rust out

Using a jigsaw or angle grinder cut out the rust. Mark the area you want to cut with a marker pen using a straight edge. Then file the edges.

Step 5 Making repair panels

You can use old panels for this or do as i did, buy some some 1mm sheet metal off of the bay of flea's. Six sheets of 450mm x 400mm for £10, This makes things easier for measuring, cutting and it's less to clean up. Measure the hole you have cut, mark the sheet and measure the hole again. As the old saying goes measure twice cut once. This saves on wastage. Top tip Cut to the outside of the marker line so that the repair panel is slightly too big. Its easier to file it down to fit than having to do the whole job again because it's too small. Then trial fit your repair panel.