Thought I would start a new page for the reconstruction work,
Having removed all the outer parts that were in the way the little rust trap was revealed so today I cut the rotten part out of the top and cleaned all the debris out.
Also gave the under guard area a good going over with a wire brush to remove all the loose dirt, sticky BS and loose paint.
A fair amount of dirt in there.
Looking better now
The lower part is still relatively solid so a little more clean and grind first
The light spots are the holes that were originally visible from the engine bay.
This piece will need to be cut out and replaced.
This level of rust damage is not seen.
It appears as little bubbles in the paint,
Cleaning the outer part back and repainting the area is a temporary measure only as the cancer is still in there growing slowly.
This is why I decided to go in hard and treat every place I could and stop it coming back.
Another day of cleaning the panels. Coming along nicely.
Slightly out of focus showing light from inside.
This was up behind the the top of the LH guard.
Water running down the windscreen and across the bonnet
would have collected here and dripped down inside the LH footwell.
Probably the reason that there was Black Stuff (BS) slopped around the
windscreen rubber and some other places. When the leak was somewhere else.
Another hole from outside, this one in the lower part of the footwell.
Found it after removing lots of BS from around the area.
Left side floor. The result of the leak that the DPO couldn't find or fix.
Terminal rust, I was aware that it was less than perfect and just cleaned it little
and sprayed some black paint over it.
This time I got in a bit deeper and scraped out the white stuff that had
been put over and under revealing several holes.
From underneath. Whatever the white stuff is it was just plastered over the rust.
The floor will need to be cut out and a new piece welded in.
No point in doing half a job.
That little rust spot on the right hand guard had allowed dirt and moisture to get into the bottom of the A pillar. There is a small rust hole in the right hand sill as well but when I probed around and cleaned the dirt out it seems the right side sill and floor are in much better condition than the left. Thinking using rust converter, then flushing it out with water before giving the sill interior the Fisholene treatment.
The left hand sill also seems to be in reasonable condition. I will strip the paint off and see what is underneath before giving it treatment as well.
Some more pictures of the floor sections
Computer adjusted the order, this is the drivers side which has superficial rust but no "improvements"
Left side front floor showing the rusted out holes (illuminated from below)
Whatever the white stuff was it was very difficult to remove.
So it looks like the entire floor will need to be cut out
and a new panel made and installed.
That this side is so bad is a direct result of water entry
over time and probably through the hidden little hole I mentioned earlier.
Some more pictures 2January 2013
Words to follow :-)
Three pictures of door limit strap that has
no apparent easy method of removal.
As with all problems like this we are allowed to look in the book.
Close up of previous repair from a different angle,
this will be cut out and a new piece shaped and hammer welded in place.
Close up of damaged lower area.
Left front guard showing area to be fixed.
Top of left front guard, showing rusted away channel area.
Was covered up with bog.
Top inside of left front guard.
Inner stiffening part had rusted away but rust had not shown through to outside.
Inner view of left front guard, showing rusted inner part covered up by previous repair work.
Lower part of left guard, shows previous rather rough repair work
The preceding pictures are the start of work on straightening and cutting out damaged areas now that we can see what is required. The repair of the left front guard is the most demanding task as it will be very visible. All the repairs underneath will be mostly out of sight once completed.
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