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.

 

the new bit tacked in a little

 

From under, this was an absolute bitch to shape.

 

Good luck man.

 

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.

 

This is the piece I shaped and welded in, I'll just post the shaped bit sitting in the hole.

 

That new metal in the firewall are looks like a clean graft.Good luck.

 

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.

 

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.

 

Nice welds.Remember to fill them after its done.