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Old 12-06-2010, 10:32 AM   #1
inferno363
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Default Rust Repair

I haven't been real active on the forums the past couple years as my e30 has had a number of issues that while working through college I didn't have the time or money to deal with. So it sat in my parents pole building collecting dust until this fall when I got settled in my "grown-up job" and decided to give it some much needed attention.

This all started with a rusted out fuel line and as I took the old line off I noticed the floor boards were in pretty rough shape. So under the knife she goes.

I gutted most of the interior and cut the carpet out. (For those of you who haven't removed the carpet in your e30 it's the first thing they put in the car so you either pull entire dash out or cut the carpet in a few places. I chose to cut mine)

So I've been working at it a few weeks now and this is where I'm at :









The passenger side is in about the same shape. It looks like water was comming in through a hole in the engine compartment up by the fuse box then sitting in on the floorboards under the carpet.

While doing all this I found a big bondo patch in the drivers fender from the PO....





So I'm gonna take that to work and use it as an excuse to practice TIG welding.

It's a lot of work but it is fixable. It's just gonna take some time. Unfortunatly I moved about 30 miles from my parents and I don't have a garage at my place so I only get to work on it once or twice a week.

Anyway I'll keep this updated with my progress and any lessons I learn along the way.
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Old 12-06-2010, 10:51 AM   #2
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i love tig welding, i hate rust repair. looks like something i wouldnt want to do. have fun and good luck
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Old 12-14-2010, 10:54 AM   #3
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new fender maybe?
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Old 12-14-2010, 11:29 AM   #4
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Looking at this, I almost miss welding rust on my car
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Old 12-15-2010, 12:19 PM   #5
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Quote:
Originally Posted by CHIF8008 View Post
new fender maybe?
I think I wanna take a crack at forming up a new lower half and welding it on. If it doesn't come out all that well then yeah I'll just get a new one.

Quote:
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Looking at this, I almost miss welding rust on my car
Almost is the key word there. You really don't miss it, trust me.
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Old 12-15-2010, 12:48 PM   #6
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Haha, perhaps I'm mistaken. But I do love doing major things to the car, which shows progress instantly, and that is welding rust!
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Old 12-16-2010, 09:05 AM   #7
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I replaced both the passenger and driver side floor pans earlier this year as well as part of the firewall on both sides. It sucked at first because I've never done body work before but it ended up not being too bad especially since the floors are hidden by carpet then covered with seam sealer and undercoating. I tried to emulate a thread on here where the guy made exact replicas of the floor panels from scratch.. he had a lot more patience than I did. I couldn't see myself doing an exterior panel where perfection is critical.
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Old 12-17-2010, 09:21 AM   #8
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Quote:
Originally Posted by winchester View Post
Haha, perhaps I'm mistaken. But I do love doing major things to the car, which shows progress instantly, and that is welding rust!
I know you mean. This kind of work does give you instant gratification and I always feel good about my progress at the end of the day.

Quote:
Originally Posted by omniscient View Post
I replaced both the passenger and driver side floor pans earlier this year as well as part of the firewall on both sides. It sucked at first because I've never done body work before but it ended up not being too bad especially since the floors are hidden by carpet then covered with seam sealer and undercoating. I tried to emulate a thread on here where the guy made exact replicas of the floor panels from scratch.. he had a lot more patience than I did. I couldn't see myself doing an exterior panel where perfection is critical.
It's nice to be able to practice some of the body work in places you can't see that way you've got some experience under your belt before you go to do it some place visible. I did some patches in the rear wheel wells about 5 years ago or so and learned a lot. When I went to do the rear valance afterward, it came out a lot better than it would have had I just jumped in.

I'll have to dig around and see if I can find that thread. I'd like to see how he went about it as there are places that I'm not sure exactly how I'm going to handle yet.
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Old 01-02-2011, 01:44 PM   #9
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look like a big job, good luck with it,and let us know how it goes!
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Old 01-24-2011, 04:17 PM   #10
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Looks very much like my rustbucket, including the seam in the inner wheel house area. It made me really sad to see that on my car.

Do you have any pics of your frame rails?
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