I read on here about the problem with dirt building up behind the fuel filler neck, leading to rust. Based on this I decided to drop the fuel tank out and take a look. The tank was only held on by one bolt as the other had snapped so will have to fix that but I think this will be requiring my attention first:

The more I poked it with a screwdriver, the worse it got, thought the back end was a bit sloppy. The scariest bit is I jumped this off a bridge (NOT on a public road) a few days back and got some serious air, I'm amazed it didn't just fold in half upon landing.

I'm not sure I can even got in there to clean it up and weld it. Anyone got tips for this?

Thanks

thats unsafe, even to weld scrap it

edit: u have you are axle arm almost loose with that rust it wont hold for long thats scary

Edited 30 July, 201115 yr by mad-dean

I don't see how, the axle bolts to a really thick bar that's unaffected by the rust. the missing metal is only the shell. I've decided to get a pro in anyways to have a look for me.

it doesnt matter about that bolt what matters is where the clamp so to speak joins to the body which is obviously too rusty

I see what you mean. I'm gunna go and clean up that bit with a wire brush to see how bad it is, will post a pic of what's left.

Holy oxidated metal Batman!

That's some heavy shit right there, any thing can be repaired but you have to ask of its worth it. Best bet is as you say clean it up as best you can and see where you stand. The thing with rust is that it tends to look a lot worse than it actually is and once you get it back to good metal you have a better idea of what can be saved and what else would need cutting out.

Edited 30 July, 201115 yr by McLOVIN

Holy oxidated metal Batman!

That's some heavy shit right there, any thing can be repaired but you have to ask of its worth it. Best bet is as you say clean it up as best you can and see where you stand. The thing with rust is that it tends to look a lot worse than it actually is and once you get it back to good metal you have a better idea of what can be saved and what else would need cutting out.

how did i know you would pop up eventually every post lol do u reckon that can be salvaged

Holy oxidated metal Batman!

That's some heavy shit right there, any thing can be repaired but you have to ask of its worth it. Best bet is as you say clean it up as best you can and see where you stand. The thing with rust is that it tends to look a lot worse than it actually is and once you get it back to good metal you have a better idea of what can be saved and what else would need cutting out.

how did i know you would pop up eventually every post lol

You dont get a post count like that from sitting and reading

Holy oxidated metal Batman!

That's some heavy shit right there, any thing can be repaired but you have to ask of its worth it. Best bet is as you say clean it up as best you can and see where you stand. The thing with rust is that it tends to look a lot worse than it actually is and once you get it back to good metal you have a better idea of what can be saved and what else would need cutting out.

how did i know you would pop up eventually every post lol do u reckon that can be salvaged

Jesus that's bad. What car that on like ?

It's a Mk2

And you're wrong, it's not scrap. I just cleaned it up and here's what I found.

The axle is held on with a u shaped bracket which is solid, this is bolted onto a solid piece of metal, in fact the only metal missing is on the front face, everything else is fine. Once I have welded a plate of 2.5mm steel on it'll be as strong as it ever was.

Holy oxidated metal Batman!

That's some heavy shit right there, any thing can be repaired but you have to ask of its worth it. Best bet is as you say clean it up as best you can and see where you stand. The thing with rust is that it tends to look a lot worse than it actually is and once you get it back to good metal you have a better idea of what can be saved and what else would need cutting out.

how did i know you would pop up eventually every post lol

You dont get a post count like that from sitting and reading

Dean It depends what else is being hiden but I've seen much worse repaired before. Thing is once its all cleaned up and been cut back to good metal it won't look any where near as scary as it does in those photos. End of the day its just a hole in some metal, clean it up, cut back and weld in some strong metal and you no longer have a hole. It's not in view so doesn't have to be blended in with the body work to look tidy or owt, shape some decent thickness plate to suit the shape then weld it in and cover in underseal, job done

It'll have an MOT before it goes back on the road anyway so if it really is unsafe it'll fail.

This is nothing compared to my KA, that was almost pure rust, the only thing holding the floorpan in was the carpet. Lower wishbone mounts were non existant. Sills were made out of newspaper and glue. I brought that car back from the dead, mot'd it, then blew the gearbox the week after.

Boom, and there's the pictures to prove it, doesn't look any where near as scary now. Sure be a nice easy repair there mate

Check out my build thread,in the MK2 members gallery. You'll see the old shell in there,and pictures of why i re-shelled it - pictures similar to yours.

We're not talking any old panels here,we're talking seatbelt mounts and axle mounts,with the chassis leg being the severed backbone.

If its to be repaired,its gonna be a big job,with the entire area replaced.

If you are going to try and fix that and then use it , please make sure you fill a donor card in first

looks much better now chap.

If you are going to try and fix that and then use it , please make sure you fill a donor card in first

I have been driving it around in this state since I bought it, as did the previous owner, if it was gunna fall apart I think it would have have happened by now.

I think you guys are making way too much of a big deal out of this, the bit I'm replacing isn't exactly subject to high load. Plus, once it's been welded over there will be as much, if not more metal, as when it came out of the factory.

Steel isn't like wood, when you patch steel it becomes one piece again.

dont just make it pretty for mot man,make it safe for yourself or the next owner

dont just make it pretty for mot man,make it safe for yourself or the next owner

Some good advice there. I don't care too much about the MOT man, I am far more concerned about my/ my passengers safety.

I will first weld up the outside and then weld inside as well. If the seatbelt mount can't be saved I'll remove the rear seats and belts altogether, better safe than sorry.

nothing a day with a welder cant sort assuming you can weld ok

lets face it its been driving around several years in a unsafe state and held up to being jumped over a bridge lol

tbh i bet lots of em are frilly when the tank is off , its just some folk are too gormless to notice

Yeah, I worry more about the people unable or unwilling to take their tank off.

I'm pretty sure I can weld ok, I repaired a motorbike frame after it cracked (crappy chinese thing) and that stood up to some serious abuse including a crash.

Well, today was the day I finally got out there and welded it. Seats and carpets out which revealed another bit of surface rust, til I jabbed it with a screwdriver, then the suspension turret got all religious on me,

It ain't pretty but it's very strong, it was one piece of steel, the extra lines of weld were where I slit the sheet with the grinder to weaken it so I could bend it to shape. I just hope I left enough room to get the fuel tank back in.

Got a mild case of arc eye right now so I'll let the pictures say the rest.

looks plenty strong enough , few more years life in her now

shame about the burnt carpet on the turret lol

Nice repairwork. Makes me wish I could weld :(

mine was as bad as that but i managed to grind it all out and plate weld it all back up. glad you saved it.