Unibody rust weld repair

Basic needs related to restoring a 6er including
Electronics, Bodywork, Welding, Painting, Engine Swap, etc
Post Reply
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Unibody rust weld repair

Post by LandShark »

I will load the pic soon but I have a rust hole above the front jack point. The jack point is weakened but mostly intact.

Peek-a-boo, wire harness.
ImageUnibody rust hole above left front jack point. by Matt Squirsh, on Flickr

Im making some patterns out of 1/16" (1.5mm) steel to weld up 3 unibody rust holes in the area under the left wing. Im familiar with the risks of doing this and have access to a quality MIG setup. Any tips for this repair?
Karmann, German for extra rusty.
User avatar
olympia57
Platinum Member
Platinum Member
Posts: 1389
Joined: Thu Sep 13, 2012 1:47 pm
Location: Ireland

Re: Unibody rust weld repair

Post by olympia57 »

That's not the jacking point , that's on/in the sill ( rocker ) .
I believe that the square pad in your photo was used to transport the shell during prep/painting at manufacture .
The pad serves no purpose and providing you are not seeking to preserve the 100% originality of the car , can be removed. They allow the build up of road dirt leading to rust ( as you have found out .....)
If you wish to retain it I'd remove the carpet and underlay ( most important :wink: ), cut out the rot and replace with fresh metal , fabricate a new pad and then weld back onto the new metal underneath .
I removed both pads from mine when I restored the car A) to remove a source of future corrosion and B) to give the Lokari liners I fitted, a flusher much better fit.
'Bye the way , that circular plug to the right of the rusty area is the sunroof drain tube exit . I presume you have no sunroof on your car , if you do it's draining into the sill cavity :shock:
Good luck .
Don
1981 635 series 1
wattsmonkey
Platinum Member
Platinum Member
Posts: 1649
Joined: Mon Jul 16, 2007 2:58 pm
Location: Cheltenham, U.K.

Re: Unibody rust weld repair

Post by wattsmonkey »

As Don says. I've had this argument with E28 owners having learned the hard way that this is NOT a jacking point, even though it's labelled "lifting pad" on real oem.

I have removed them from my M as part of the restoration along with the jacking points on the sill. Instead, I've welded reinforcing plates onto the chassis rails and carry a small scissor jack in the boot.
"Most of it necessary; all of it enjoyable." LJKS
'84 635CSi, dogleg...itbs and supercharger????? Eaton Mess
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Re: Unibody rust weld repair

Post by LandShark »

Golly, its such a convenient jacking point (I use a rectangular piece of wood in there). I think I'm just going to cut the rust, clean it up, treat the underlying metal and reinforce it.
Karmann, German for extra rusty.
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Re: Unibody rust weld repair

Post by LandShark »

I see that the "frame rails" are the appropriate part to jack on. Mine are dented pretty good (that's the condition they were in when I acquired the car) #-o
Karmann, German for extra rusty.
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Re: Unibody rust weld repair

Post by LandShark »

I'm using POR 15 on the peripherals here. The fender is obviously rotten to the core, but I have this idea of working chain/bar oil into the seam to to treat the unseen . But then top coating it for aesthetics will be difficult.

http://www.type2.com/library/body/baroil.htm

ImageRotten at the crease by Matt Squirsh, on Flickr
Karmann, German for extra rusty.
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Re: Unibody rust weld repair

Post by LandShark »

On this episode of this old Saab... nah just kidding. Stitching 16 gauge wasn't too bad. I used a Hobart MIG welder with 100% CO2 mentioned in another post. Just some cheesy plates mainly to reinforce that square so I can continue to use it for my "jacking pleasure".

Image20180125_161540 by Matt Squirsh, on Flickr

Image20180125_161343 by Matt Squirsh, on Flickr

Image20180125_133901 by Matt Squirsh, on Flickr
Karmann, German for extra rusty.
User avatar
tschultz
Posts: 2513
Joined: Wed Jul 07, 2010 10:54 pm
Location: Colorado
Contact:

Re: Unibody rust weld repair

Post by tschultz »

Is that your personal garage!!?? :D
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
User avatar
LandShark
Posts: 210
Joined: Tue Oct 29, 2013 6:38 am
Location: Soccoro NM USA

Re: Unibody rust weld repair

Post by LandShark »

That's Jeffs Saab Shop. Although my dream garage would have a 2 post lift. And an espresso machine.

https://www.google.com/maps/place/Jeff' ... 06.5256959
Karmann, German for extra rusty.
SenorShark
Posts: 133
Joined: Thu Feb 25, 2016 4:31 am
Location: Dallas, Texas

Re: Unibody rust weld repair

Post by SenorShark »

LandShark wrote: Thu Feb 01, 2018 2:32 am That's Jeffs Saab Shop. Although my dream garage would have a 2 post lift. And an espresso machine.

https://www.google.com/maps/place/Jeff' ... 06.5256959
Gotta get some 'fuel' aka coffee somehow...Also, working on a lift is so much better than laying on the ground.
------------------------------
85 635CSI Euro - Schwarz
viewtopic.php?f=25&t=26741
85 635CSI Euro - Diamantschwarz
viewtopic.php?f=25&t=29839
Others:
'86 Porsche 944
Post Reply