Thread: Dune - Rust hole 001

Well my thouhts would be to treat the rusted area and do both inside and out with a good rust converter then fill the hole with bog and then treat the door with rust preventive ...

Or if you have access to a welder cut the offending rust out then make a patch to fit neat in the hole you now have and weld it in taking care to not heat the area too much a wet rag is your friend and if ya guna weld on ya truck have a assistant handy with either the garden hose or fire extinguisher and dont forget to dissconect ya battery ...

then once welded grind off prime with rust preventive paint and trest the inside of the door frame to a good preventive by drilling holes in the top of the door frame and tipping in sum tectyl or other rust preventive

cheers

Chris

Looking at the size of that and the grot inside the door I reckon that's got to be welded and repaired properly. Once welded, I'd look at using something like this:

http://www.fyshwick.autobarn.com.au/...nav_top_id=114

I've just stumbled across this stuff and it works REALLY well. Seems a heap better than the old phosphoric acid conversion process.

If you just want to do it relatively cheaply.

Once loose rust is removed, treat the area with a rust converter (plenty come in small bottles) and then coat inside/out with an inorganic/zinc rich primer, common retail products are called Cold Gal etc and come in a spray can. Zinc rich primers have the advantage they still offer good protection for small spots that get missed when coating. Don't put Zinc rich primers on thick.

If you jut want to bog it up, cut a small square piece of tin/metal that will fit through the hole at its angle, Drill a hole in the tin and tie a piece of string to it. Feed the square tin through the rust hole and once through carefully pull it in position to cover the rust hole from the inside. Push the plate back slightly and use any flexible adhesive, mastic, liquid nails whatever takes your fancy there, pull the plate back into position, let adhesive cure. Then bog and sand smooth, spray some more zinc over it so it looks tidy (tidy enough anyway).

It’s a cheap repair (not structual though) and the material used will do all the little spots on the vehicle.
Technically you should always top coat over primers, but if you don’t care about the looks, then I prolly wouldn’t bother.

But, do look at why the spots have rusted. Is it simply dodgy Land Rover coachwork or is water getting in and can’t get out?

Is that the bottom corner of the door top? Are Defender doors still 2 piece and they have simply welded them together and clad the alum skin over it? If so, I’d be looking at removing the door trim and see if you can’t drill some holes between the 2 door halves. They will act as both drain holes if it’s water and as breathers for the closed in section if it’s moisture/condensation.

Looks like poor drainage from the bottom of the rear window (it's a Series 111, DarrenR). Mine had extended stainless drain tubes fitted by a previous owner because it is a known weakness. While you have the door apart for the fix and to check the frame under the glass, think about enlarging the drains.

oh ok, dunno why I had Defender in my head. Yeah it's a bad spot for early Series landies, as you said definately clear out and enlarge drain holes.

Am I right in seeing this is the two halves of the door welded together?

Best regards
DarrenR

Originally Posted by DarrenR

oh ok, dunno why I had Defender in my head. Yeah it's a bad spot for early Series landies, as you said definately clear out and enlarge drain holes.

Am I right in seeing this is the two halves of the door welded together?

Best regards
DarrenR

Yep, that's how they are. Neater welding than on mine - must have been a Wednesday. The front doors are bolted but the rears are one piece.

Cut it out, weld a plate in and drill a hole to squirt Fishoil or similar in it.

Then put a grommet in the hole.

you will never stop it rusting, but you can slow it down.

Grommet has the same problem....

Originally Posted by sclarke

Cut it out, weld a plate in and drill a hole to squirt Fishoil or similar in it.

Then put a grommet in the hole.

you will never stop it rusting, but you can slow it down.

Grommet has the same problem....

If you put grommet in a grommet, would the whole vehicle just dissappear Be like folding itself inside out