Outer Limits 4x4 Board

Just reading the fibreglass thread and got thinking about rust repair. As some would know Nicbeer has a little bit of rust, and for some time now has been chasing a tub to do a body swap. IMO he is better off repairing the original body then to buy a new body and swap.

Sometimes it’s worth picking up a restoration book and having a read about rust repair. Hell you want to see what those crazy poms will repair, because of the salty roads. I have an escort restoration book, it’s a hard cover with a yellow MK1 on the front. I would recommend it to anyone even if it’s not an escort they are repairing.

In nick’s case his rear tub is rusted where the door is bolted on and the rear door is sagging. (same as my old rig but it was repaired.) So here is what I was thinking he could do. Firstly cut out the part that is rusting, then get some sheet medal and weld/brass it in. The sheet metal can be thicker to make it easier to weld . This way it is gusseting it was well. Now he has already taken to weight of the spare off the rear door, so the next step would be to make the rear door lighter…. Keeping in mind this isn’t his daily driver, glass is the heavy. Just a thought, the glass could be replaced with Perspex. Then go nuts on the bracing and cut as much as possible without making it to flimsy.

Okay I’m getting side tracked here but has anyone done some rust repair, or have advice as to how it can be fixed easier and cheaper then a body swap.

i suggested nic should do the ute chop ....... his biggest problem is lack of welding skills to cut and shut it ...(therefore the rust repair is out too) ...
i have offered my welding services ... but the last time nic was up here we all got carried away in a salt lake (cant imagine where the rust comes from )

so unless you can help out with anyone who can weld dewse . i think nic will have too keep lookin for a bolt on repair method (2nd hand body)

any welders in perth want to weld for booze??

alternatively - who does welding courses? id love to learn how to do it.

so alien you,

cnat spel

and

cnat wled

Yeah okay that is a fair point. The other method to repair the rust is to cut some metal out and pop rivet it in. Then tap down and cover with bog. Honestly not the prettiest way, but have a look at his heaper anyway.

I kinda reckon it’s cool that he has a built high top, and think it’s part of the appeal, Cutting it up or replacing the body will make it like any other rig.

My old boy is a welder, but he’s fairly busy these days, travelling oz.

Put and internal bar in it, clean the body up a bit, and wheel the hell out of it nick!

I've looked at it with a mate. thats not the only rusted out bits in it.

The rear door striker is missing now. rust has made it go missing.
Around all rear windows rust eaten. top window is held in with tape.

thought of a ute but being a hightop would look wierd.

Got a rear tyre carrier coming hopefully (cheers drew)

Body is farked.

cheers

Nic

v8patrol has done some amazing rust repairs. pm him to post up in here.

DeWsE wrote:Yeah okay that is a fair point. The other method to repair the rust is to cut some metal out and pop rivet it in. Then tap down and cover with bog. Honestly not the prettiest way, but have a look at his heaper anyway.

I kinda reckon it’s cool that he has a built high top, and think it’s part of the appeal, Cutting it up or replacing the body will make it like any other rig.
My old boy is a welder, but he’s fairly busy these days, travelling oz.
Put and internal bar in it, clean the body up a bit, and wheel the hell out of it nick!

I like the ideas. As long as it looks legalish. Possible i guess. Been looking for another hightop as well.

A body swap appeals to me to get rid of a few problems as well, gives me some new ideas as well.

cheers

Dude if your living in Wanneroo now we will take care of it, you go and cut the plate or what ever you are going to replace it with and we can weld it in. Even a crappy noob welder like me can do that. then tap it down, fibreglass it and paint it. Bog covers a multitude of sins

Wolverine wrote:Dude if your living in Wanneroo now we will take care of it, you go and cut the plate or what ever you are going to replace it with and we can weld it in. Even a crappy noob welder like me can do that. then tap it down, fibreglass it and paint it. Bog covers a multitude of sins

Yay someone with the exact same attitude as me

While your at it Nick take the top windows out and delete them with some steel.

Hehe could do that tot he side windows as well, so it will be a panal van

DeWsE wrote:

Wolverine wrote:Dude if your living in Wanneroo now we will take care of it, you go and cut the plate or what ever you are going to replace it with and we can weld it in. Even a crappy noob welder like me can do that. then tap it down, fibreglass it and paint it. Bog covers a multitude of sins

Yay someone with the exact same attitude as me

While your at it Nick take the top windows out and delete them with some steel.

Hehe could do that tot he side windows as well, so it will be a panal van

Dewse: thats what i was thinking off. gonna have a look today if got chance at the top windows. side windows might keep as it would be a pain looking around when driving when there are paneled up. but have thought about making them non openable with perspex gluing them in.

Why not cut out the rust on all the flat areas lay down a patch of fibreglass on top of it and add ressin... do this on both sides of the hole make the edges neat... no?

my thoughts were to make it an extra cab.
just enough tray to have a recovery drawer , plus if done right , could use the after market spare tyre carrier roll bars would tie in nicely

use original rear door glass in the new rear panel and the extra cab length would allow for the high top to remain and not look

Years ago I lived at Gunnedah in NW NSW and one of the panel beaters in town was running vehicle restoration courses at the local TAFE.

The way it worked was you enrolled in the course, brought in the vehicle you were restoring and the panel beater gave you advice and guidance to get the job done. It was a great idea and the course was always full.

If you hunt around you might find something similar in your area. Vintage car clubs are great at this sort of thing.

Just a thought

Cheers

Clive

nicbeer wrote:but have thought about making them non openable with perspex gluing them in.

Use lexan otherwise if you leave the perspex out in the sun it will craze. and plus lexan is stronger.