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Unibody rust weld repair

Basic needs related to restoring a 6er including
Electronics, Bodywork, Welding, Painting, Engine Swap, etc
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LandShark
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Unibody rust weld repair

Post by LandShark » Sat Jan 13, 2018 4:49 pm

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.

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olympia57
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Re: Unibody rust weld repair

Post by olympia57 » Sat Jan 13, 2018 11:33 pm

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
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Re: Unibody rust weld repair

Post by wattsmonkey » Sun Jan 14, 2018 9:34 am

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

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LandShark
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Re: Unibody rust weld repair

Post by LandShark » Sun Jan 14, 2018 2:54 pm

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.

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LandShark
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Re: Unibody rust weld repair

Post by LandShark » Sun Jan 14, 2018 3:06 pm

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.

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LandShark
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Re: Unibody rust weld repair

Post by LandShark » Tue Jan 16, 2018 1:52 am

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.

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LandShark
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Re: Unibody rust weld repair

Post by LandShark » Fri Jan 26, 2018 2:51 am

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.

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tschultz
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Re: Unibody rust weld repair

Post by tschultz » Wed Jan 31, 2018 4:18 pm

Is that your personal garage!!?? :D

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LandShark
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Re: Unibody rust weld repair

Post by LandShark » 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
Karmann, German for extra rusty.

SenorShark
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Re: Unibody rust weld repair

Post by SenorShark » Fri Mar 02, 2018 3:26 pm

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.
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