This car in otherwise good mechanical condition (see Power Steering Pump Replacement and New Struts ) has some rust along the top of the screen, two roof points, and in the rear sills and quarter panels.
The original screen is chipped in several places and has a crack in one corner, and should ideally be replaced. In any case, an effective repair requires that the screen is removed so the rust under the rubber molding can be treated. A new screen and molding will be fitted once the repair is done. If the screen is not removed and just the visible rust covered, the rust will reappear within months.
The corrosion pitting is quite severe, so sandblasting the affected areas is required to get a clean metal surface. Most of the rusted sufaces can be treated before the screen is removed. Glass removal and replacement was subcontracted to a local auto glass company.
Expected rust under the screen adhesive. Most of the rust was minor surface pitting. No welding was required.
The painting completed and the new screen installed.
The Sills and Rear Quarter Panels
This side sill appears quite solid, and likely only the outer skin section will need to be replaced. There is probably a hole somewhere on the inner sill box section, and this will have to be located and repaired to prevent further water entry. Note the jack point on the lower sill seam.
The rusted inner sill box section has lost structural integrity, and this is why the sill has been crushed when someone attempted to jack the car. The inner sill section requires rebuilding with 16G steel to provide a safe jack point, and the outer skin section fabricated and replaced.
These rear guard edges are rusted under the mudflaps, at the lower seam and further. Some major fabrication to repair the folded edge, panel contour and the inner guard will be required.
Doing the repairs.
As expected, the rust damage was a bit more extensive, so a large area of rusted metal had to be removed. Five separate pieces were required to restore this quarter panel: two outer skin sections and three inner guard sections.
The LHS lower seam rust was more extensive than visible.
The LHS outer quarter panel skin. Note the inner guard also requires a repair section.
The LHS wheel arch outer skin and inner guard (not visible) repair. The lower seam area is not yet repaired. The reconstruction time for just this quarter panel was 7 hours, excluding refinishing.
LHS rust removed from sill, prior to repair.
The inner guard at the LHS sill end in the wheel well, after the underseal was removed to expose the rust.
The RHS sill jack point partially repaired, during rebuilding of the internal structure.
The RHS rear sill jack point internal structure. The rusted box section bottom and edge have been cut away, and the three new sections formed with 16G steel. The angled sections outlined in blue, yellow and orange form an internal box structure that will support the weight of the car. External body sections are formed with 20G steel. If the internal structure is not recreated, the first time the car is jacked will cause the sill to crush again.
The end plate on the box section (not yet installed) provides additional strength.
The internal rusted regions have been wire brushed as far as possible and chemically treated to slow the remaining surface rust.
As with all bodywork, the preparation before painting defines the result. Body filler is used to set the contour and all bumps and dips have to be absolutely smooth before the paints are applied.
LHS quarter panel after painting.
RHS quarter panel after painting.
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