1st Generation Specific 1979-1985 Discussion

Rust Hunting Update

Old 03-10-2003, 11:54 PM
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Hey guys, just thought I'd give you all an update on my rust hunting, metal cutting, new metal shaping, welding adventures on my series 3 ((Aus 84) (83-GLS-SE equiv)).

I've been busy recruiting my friends and their tools to help me in my quest. I've done heaps, yet f**k all compared to whats left or haven't found yet but anyway, I thought I'd post a few pics. My ISP is having technical difficulties, so I'm going to attach them rather than link them.

Here goes...

First couple are of one corner of the firewall.
Attached Thumbnails Rust Hunting Update-dsc02831.jpg  
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Old 03-10-2003, 11:56 PM
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the new bit tacked in a little
Attached Thumbnails Rust Hunting Update-dsc02855.jpg  
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Old 03-10-2003, 11:58 PM
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From under, this was an absolute bitch to shape.
Attached Thumbnails Rust Hunting Update-dsc02856.jpg  
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Old 03-11-2003, 12:03 AM
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Good luck man.
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Old 03-11-2003, 12:11 AM
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The roof section I had to cut out

Theres a factory weld along here that splits one piece of metal into two for the roof. On cold mornings, condensation sits along here and slowly rusts.
Attached Thumbnails Rust Hunting Update-dsc02848.jpg  
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Old 03-11-2003, 12:16 AM
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This is the piece I shaped and welded in, I'll just post the shaped bit sitting in the hole.
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Old 03-11-2003, 12:17 AM
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That new metal in the firewall are looks like a clean graft.Good luck.
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Old 03-11-2003, 12:19 AM
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This is the bit I replaced the air-con box holder piece with. This was the hardest thing to shape so far. I swear I musta been a blacksmith in a previous life to have got this flush.
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Old 03-11-2003, 12:25 AM
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This is one side of the rear wheel rust removal. Its stiched welded in. tack tack tack tack between tack between tack tack tack, etc I have to grind it down then fill in any bits i missed.
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Old 03-11-2003, 12:45 AM
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Nice welds.Remember to fill them after its done.
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