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Posted 18 November 2003 - 08:08 PM
Posted 18 November 2003 - 10:38 PM
1. Removed all the really loose rust with a heavy wire brush
2. Use a rust-converter spray (or similar) let dry. Give it another coat. Let it dry.
3. Prime the area (and inside the hole) with a sandable primer spray paint.
4. Fill the holes & voids with a water-proof expanding foam in-a-can stuff. They sell this at your local home improvement store. Make sure it's maximum expanding and water-proof!
Mask off any areas you don't want it to stick to and wear gloves cause it dosen't come off! Let it dry overnight.
5. The next day take a sharp knife and carve off the excess foam
6. Blend the foam and edges of metal together with your favorite fiberglass. I used marine grade water-proof fiberglass.
7. Sand area till edges are blended and smooth. Repeat step 6 if necessary.
8. Mask off areas and spray with a sandable primer. Let dry.
9. Lightly sand area till smooth
10. Spray final coat of Paint.
Posted 18 November 2003 - 10:59 PM
POR15 is expensive but worth every penny, so is stainless. But I know that an area fixed this way will never give me a problem again.
Posted 18 November 2003 - 11:19 PM
Posted 19 November 2003 - 01:09 AM
Posted 19 November 2003 - 06:54 AM
Hate to chuck cold water on the foam theory but its a real b***h of a stuff, I did a car of mine a couple of years ago. It made an excellent job of filling in the gap and was a really convincing sounding body panel when it came inspection time but within a month it has started rusting again but further along from the repair (I filled the sills). The dam stuff actually holds the moisture against the sheetmetal and gives it a great atmosphere for rust to grow!!
Posted 21 November 2003 - 11:24 PM
Posted 21 November 2003 - 11:28 PM
Posted 21 November 2003 - 11:34 PM
Posted 21 November 2003 - 11:35 PM
Posted 21 November 2003 - 11:43 PM
The sprays/brush-on-stuff work, but for a limited time... they're what I'm using right now as a temporary stop gap to hold my Loyale together until I pick up its replacement. If'n you're gonna be cutting and welding later this spring, I'd go this route, and fiberglass-patch any rot holes.
I wouldn't trust the foam stuff... I've heard too many thoughts about it holding moisture against the sheetmetal.
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