How do I start with this mess...

[phibbzy]

http://imgur.com/a/2JiVw

Since shes out of action until a new rad/IC arrives I've started on the more annoying jobs on my defender.

I have no idea where to properly start with this mess. The PO had sealed the entire hinge area up with clear sealant but of course it still leaks through the bolts.

I'm thinking of stripping the entire area back, repairing the rust holes with knead it and the area with rust killer and finishing it back by painting the entire front there.

Any suggestions on how I can get this fix looking clean?

[Lotz-A-Landies]

There is internal rot, you may have to replace the firewall in not too much time. One less severe option is to cut out the corner and fit some repair sections.

First action would be to cut out a small window around the hole to get back to good metal and weld back in a piece of sheet. The window will at least let you know how much of a problem is inside. (If you can borrow an endoscope even better)

Treat the inside with Penetrol Anti-Rust control before it gets any worst.

[phibbzy]

Damn.

Better practice my welding skills...

[phibbzy]

I started cutting the completely rusted sections out - got as far as past the hinge bracket toward the center and down about another inch. It's all cut and removed. I used a bore scope to check inside toward the center and lucky the major rust stops there as far as I can see.

I'll treat the inside however with some penetrol as far as I can then seal over the top

I'll have to wait until after may next year before I can get a solid chance to do a bulkhead swap - or even just a patch up but by the looks it will last that long without trouble.

[phibbzy]

Just to close of this thread.









Removed all the bad rust, treated the inside with rust converter then sealed up either side of the area with sealant.

I bogged up the hole, sanded back and repeated a couple of times until it was 'roughly' flat. It's tricky in an area like that to get it right.

Rust guard primer, 3 coats & 3 coats of LRC.456 white.

It's come up "good enough" to get us through the next 12 months or so. A Galvanised bulkhead is on the cards and a complete respray. The roof needs attention as well in some areas and the foot well, as well as being patched, has rust on the top of near the clutch.

[rangietragic]

At the risk of knocking your panelbeating skills,it looks a bit like i did it

[phibbzy]

At the risk of knocking your panelbeating skills,it looks a bit like i did it

Haha! What skills? First time I've ever bogged, primed or painted anything I figured I'm going to be replacing the bugger anyway, might as well practice... It looks okay from afar and it'll stop the water ingress - thats all i care about.