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Welding for MOT


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I've been welding patches to inner wings. Within 30cm of a suspension point.

 

As far as I can tell from MOT manual this repair must be a continuous seam.

I cut, prepped, shaped, clamped, welded 1.2mm steel sheet using 1.6mm rods.

(with an arc welder and Kelarc pistol).

 

So far so good, on the outside. 

 

It'll be mostly covered by the plastic wheel arch liner.

Will dress and PU seam seal it before painting, and undersealing.

 

Do I have to weld the other, harder to access, inside of the patch?

 

 

 

IMG_20201122_144007_6CS~2.jpg

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just the weld on one side should do it    grind it smooth ish and seam sealer it ...what they cant see they cant fail 

epoxy primer is worth the investment on a car you want to keep ....10x more durable than zinc182 

Ordered some grey epoxy 1K primer, not here yet.   Got the seam sealer applied in milder weather and covered again with zinc182.  It's flipping sticky stuff. Put some on other awkward s

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steveo3002

just the weld on one side should do it 

 

grind it smooth ish and seam sealer it ...what they cant see they cant fail 

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Grinded smooth-ish. A few tiny holes revealed on the other patch I did first on offside of the car, which was not as neat (no picture).

 

Reason  - my welding rods had got damp in storage so were stocking not sparkling. Dried them in an oven at 150C for 20 mins. 

Still feels very solid. Might go over those holes with the spotwelder rod.

 

 Primed the ground surface in Zinc-182.

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Some more grinding and welding rod touches later.IMG-20201206-WA0006.thumb.jpeg.d8eeca5f646aa7072c960a915a9a8f31.jpeg

I used some rattle can paint, because it was too cold for the PU seam sealer which needs +5C.

 

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steveo3002

epoxy primer is worth the investment on a car you want to keep ....10x more durable than zinc182 

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I used a phosphoric rust convertor, epoxy paint(POR15) then waxoyl inside another cavity at back of nearside arch, then welded a patch over it. 
 

I used a loudspeaker magnet to hold the patch down while I tack-welded it in place.

(see pic)

The waxoyl burned a bit of course but the VW underseal only smoulders.

Going to underseal that too.

 

IMG_20201206_161338_6.thumb.jpg.42cbf480e7abe1420503b7d0ae46e508.jpg

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Ordered some grey epoxy 1K primer, not here yet.

 

Got the seam sealer applied in milder weather and covered again with zinc182.

 It's flipping sticky stuff. Put some on other awkward side (and got some in my hair in the process 🤪. Undersealed that hidden side.

 

This side I'll paint one more time.

 

IMG_20201220_151920_6.thumb.jpg.ff15a5c7b0e9ed061315520bfa0ee71a.jpg

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  • 2 weeks later...
dvderlm

IMG-20210104-WA0002.thumb.jpeg.258a09aa48c8dd86d6bddaa1a2ccd012.jpeg

Painted again. Inner arch cover refitted. Wheel back on.

And the uglier side

IMG-20210104-WA0000.thumb.jpeg.8373b05092874204f082808aa2c83080.jpeg

The inner arch cover is sticking out a bit. I might trim off the corner so it sits more flush and maybe a bead of sealant. There was a captive screw here once upon a time. I imagine two different metals of screw and panel helped the corrosion process along.

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steveo3002

hah yeah mine went around that screw hole too 

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dvderlm

There's threaded square plastic insert things with gaps that will hold onto salty road spray, but the screw and heads are not rusted to bits. 

 

A bit like this

 

image.png.6254d589817fd9939dafe2c2f3102762.png

I might switch to expanding rubber well nuts or nylon clips.

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steveo3002

yeah i just replaced it with another plasticclip  like your pic , not great most of them have caused rust to start , but i doubt its what will finish the car off..guess they were too tight fit when new and chafed some paint off 

 

i fitted mine with a dollop of grease  

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