Rotting Inner Sills - Graphic Content Inside

[bigdaddycain]

I suppose in what way you mean "do bodywork" Sorry to see your undercarriage has gotten to that state mate... Feel for you...

[stuc]

Thought you would like to see mine before welding. This is just one side both sides were equally bad. It is quite an easy place to weld as it is simple shapes to make and patch. Yours just needs a longer section making. Might not be cheap but certainly cheaper than another Bongo. You can buy the sheet metal from steel supermarkets or from places like Hadrian panels.

http://www.igmaynard.co.uk/bongo/forum/ ... 99#p505796

[BongoMTBer]

Cheers guys.

Stuc - liking your work, especially your wheel arches. I understand you are a pro at this? Should the old rusty section be cut out before new plates go on or do you just plate over the top?

Also, you had the same issue as me with the corrosion migrating to the outer sills. How did you sort yours, especially on the lower lip where they spot weld together?

I do have a mig welder, maybe I should be doing this myself after a bit of practice on some scrap metal. My welding isn't pretty mind!

[stuc]

Hi you should cut out as much rusty metal as possible, it could be plated over but would not look prety and may come back through. Dont worry if yor welding is not neat just make a good job of cutting the patches/shapes etc. weld it up and just use an angle grinder to tidy up the welds. Plenty of brush on sealer and waxoyl and it will look fine.

[BongoMTBer]

Thanks for the advice – I have taken the plunge and ordered some 1.5 mm plate, a new mask and will be picking up my welder at the weekend.

How much metal can I cut out before the chassis collapses?

Await more gory pictures!

[stuc]

Do one side at a time, dont worry the chassis wont collapse, i think

[BongoMTBer]

Progress...

Has anyone used High Zinc Weld Through Primer? Specifically, how did you get on with 'weld through' bit?

RH side underway:





Steel has arrived, just need to get my welder back this weekend and have a practice before I attach poor Bongo.

[Gripped]

What did you use to cut the rusty metal out?

[missfixit70]

What did you use to cut the rusty metal out?

Angle grinder by the looks of the overrun on the pics

[BongoMTBer]

Ha ha, spot on Kirsty - that just juves me a bit more to practice my welding on!

And a cold chissel, drill and anything else I could find to get into corners.

Prep seems to be the most time consuming bit, but I want to get ALL the bad stuff out.

[BongoMTBer]

Used my airline and parafin sprayer to blast the sills with thinned Waxoyl today. I have then made cardboard templates to start making up the patches. Luckily, I have access to a ramp and various panel beating tools so I am hoping to make some pretty funky shapes. On looking inside though, I don't feel like I got my moneys worth with the professional cavity waxing. There are loads of dry areas, despite them being adjacent to access ports Waste of money, should have spent it on a compressor and tools to do it myself. Would have cost the same but I know I would have done it better, just maybe not as durable.

Next thing will be to apply high zinc etch, weld through primer to plates and exposed metal before attempting the welding

[bigdaddycain]

The prep work looks thorough MTBer It's just a pity you have to do any of this in the first place R.e your expensive undersealing job... You lives and learns mate... "getting what you pay for" doesn't cut it in this case it would seem. I'll stick to my cheapo (yet regular) waxoyl jobs methinks...

Can't wait to see the finished job! Best of luck

[stuc]

I agree, looking good so far. Its gonna look good when done and you should be satisfied you have done it yourself. Plent of brush on seam sealer, bit of black then waxoyl. Jobs a good un.

[BongoMTBer]

Cheers for the encouragement guys!

[bigdaddycain]

No worries... Kudo's to you for taking the job on! Inspiration to many i'd wager.