Project Rusty.

Ironstrike · May 19, 2019

dieseldog69 said:
I did get a look at it and no I was not pleased, at all

View attachment 177691

Got all excited when I got back from work, started it up and let it tick over as it's been a few weeks, was busy with a few other jobs and when I pulled out my old bit of carpet I found the sender recess in the tank was full of diesel, looks like the sender pick up and return pipes have rotted through, i knew they were crusty and had planned to replace the sender but didn't expect it to fail before I'd finished welding it up

Oh well, another day tomorrow.

Dont go up any hills with that! I eventually worked out that that what was causing the problems with mine, fuel was pouring out of the top of the tank through a dodgy seal, thus the fuel vacuum

dieseldog69 · May 19, 2019

Ironstrike said:
Dont go up any hills with that! I eventually worked out that that what was causing the problems with mine, fuel was pouring out of the top of the tank through a dodgy seal, thus the fuel vacuum

Good to know you got to the bottom of it mate, mine ought to be good now, just gotta hope the weather gets better and I can get back on with the welding

It's chucking it down out there still, started off a super nice day but turned South real fast

Ironstrike · May 20, 2019

dieseldog69 said:
Good to know you got to the bottom of it mate, mine ought to be good now, just gotta hope the weather gets better and I can get back on with the welding

It's chucking it down out there still, started off a super nice day but turned South real fast

By the look of the weather forecast it doesn't look like you will be getting much done this week. That's the bugger about driveway restorations. I found a car lift for £150 but nowhere to put it. I considered just putting it at the bottom of the drive, painting it white and putting some concrete eagles on top like pikey gate posts

dieseldog69 · May 22, 2019

F#@?+ty f#@k f#@k f#@k

Well that didn't go well did it, this was supposed to be the good side

I thought I would get an hour in on it tonight and strip the passenger side rear quarter panel off.

Pulled out all the fasteners and had to remove the fuel filler pipe and breathers as this is mounted on the rear most section of the rear quarter panel, no point trying to undo the clips just buzzed them off with the Lidl multi tool

Got a couple of nitrile gloves on there to seal it all up.

And off with the big azz panel.

Time for a look around and see whats what.

Back of the sill behind the B pillar

Not good but it was all getting chopped anyways, but the surprise came from the rotted out sill where someone had previously fitted over sill outer repair panels,

It does get worse

But that's still not as bad as it gets yet

How about the C pillar, the absolute state of this

Deeply pitted and I saw a few pin holes

Dig out the wire brush for a quick look see at what's under all that flaky scaly rust.

This is the top of the post where it seems that the seam sealer had failed and water has been driving in and rotting it away.

Oh dear, but I suppose I got a bit too excited about being somewhere near the end, that'll teach me won't it

doriz · May 22, 2019

The gift that keeps on giving

dieseldog69 · May 22, 2019

doriz said:
The gift that keeps on giving

If this thing ever stops trying to return to nature I swear it will blow itself up lol

Not sure how I'm going to fix it yet, the pitting is very deep in places and it really does look as though I'm going to have to get creative with the sheet metalwork and the welder in order to rebuild the strength lost through the rust pitting.

Maybe some sort of frame work to create datums from so I can try and keep it to profile?

@The Mad Hat Man just gone a bit crackers, you got 5 for a phone call?

doriz · May 22, 2019

dieseldog69 said:
If this thing ever stops trying to return to nature I swear it will blow itself up lol

Not sure how I'm going to fix it yet, the pitting is very deep in places and it really does look as though I'm going to have to get creative with the sheet metalwork and the welder in order to rebuild the strength lost through the rust pitting.

Maybe some sort of frame work to create datums from so I can try and keep it to profile?

@The Mad Hat Man just gone a bit crackers, you got 5 for a phone call?

You’ll work it out

Henry_b · May 22, 2019

Just put some Kurust on some surface rust on me chassis..................

Trying to find Rust is hard on the P38

Ahem..

doriz · May 22, 2019

Henry_b said:
Just put some Kurust on some surface rust on me chassis..................

Trying to find Rust is hard on the P38

Ahem..

I thought you hoovered up most of your P38?

Henry_b · May 22, 2019

doriz said:
I thought you hoovered up most of your P38?

Not yet

The Mad Hat Man · May 22, 2019

Remember Tufftee, DD. I am sure you said "there is nothing that isnt fixable - some just takes a bit longer, thats all"

good bit of shot blasting to clean it up and then re-assess the situation.

Jeremy is waiting your contact.

dieseldog69 · May 22, 2019

The Mad Hat Man said:
Remember Tufftee, DD. I am sure you said "there is nothing that isnt fixable - some just takes a bit longer, thats all"

good bit of shot blasting to clean it up and then re-assess the situation.

Jeremy is waiting your contact.

I will ping him a text tomorrow, think if I can get that whole section in good order that would be the best way forward but will have to see what spare ones are like and weigh up pro's and cons etc,.

Cheers for the find, sounds like an interesting fellow to know.

Still got my mind occupied with the spare wheel carrier mountings and can see an epic build coming off the back of this

The Mad Hat Man · May 22, 2019

But yu need a back to build off of.

dieseldog69 · May 22, 2019

The Mad Hat Man said:
But yu need a back to build off of.

Going to be one when I've finished

dieseldog69 · May 26, 2019

Think I've sourced a C pillar to repair mine, well I hope so anyways

Thought I should go chopping it up a bit today before the weather turned south and dinner at mums beckoned lol

The usual rot and grot to be found.

Big bit cut out being the old wheel tub and the bottom of the B post along with the back of the sill.

I was just going to bite the bullet and replace the rear cross member but it's a lot more with the C post and I'm just not feeling it, but never say never as it's being left until last.

I already have box section for the sill and can get the wheel tub and side panel on as well as the boot floor supports.

This could take a while longer

The Mad Hat Man · Jun 5, 2019

Crikey!

dieseldog69 · Jun 5, 2019

The Mad Hat Man said:
Crikey!

That's a good way of putting it lol

The Mad Hat Man · Jun 5, 2019

Tufftee will be a walk-in the park after that .

And a lot cheaper for you

dieseldog69 · Jun 5, 2019

The Mad Hat Man said:
Tufftee will be a walk-in the park after that .
And a lot cheaper for you

It'll get there eventually and be better than new when it's done, hopefully with a lot less muck and water traps to stop it rusting out again.

Hope I can get on it this weekend for a few hours and get some done. Got a lead on a 300Tdi being broken on my doorstep so might pop over and have a nose at whether it has something to offer, might cut the whole post off it if it's in good nick, if it's another rot box then I'm just going to fabricate it out of sheet metal and be done with it.

But first I think I'll weld up the chassis and get the box section in the sill and the floor in and then attack the rotten door post

Kiwi Jim · Jun 7, 2019

dieseldog69 said:
F#@?+ty f#@k f#@k f#@k

Well that didn't go well did it, this was supposed to be the good side

I thought I would get an hour in on it tonight and strip the passenger side rear quarter panel off.

Pulled out all the fasteners and had to remove the fuel filler pipe and breathers as this is mounted on the rear most section of the rear quarter panel, no point trying to undo the clips just buzzed them off with the Lidl multi tool

View attachment 178605

Got a couple of nitrile gloves on there to seal it all up.

View attachment 178607

And off with the big azz panel.

View attachment 178608

Time for a look around and see whats what.

Back of the sill behind the B pillar

View attachment 178609

Not good but it was all getting chopped anyways, but the surprise came from the rotted out sill where someone had previously fitted over sill outer repair panels,

View attachment 178611

It does get worse

View attachment 178612

But that's still not as bad as it gets yet

How about the C pillar, the absolute state of this

View attachment 178613

Deeply pitted and I saw a few pin holes

Dig out the wire brush for a quick look see at what's under all that flaky scaly rust.

View attachment 178664

View attachment 178666

This is the top of the post where it seems that the seam sealer had failed and water has been driving in and rotting it away.

View attachment 178667

Oh dear, but I suppose I got a bit too excited about being somewhere near the end, that'll teach me won't it

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