body repair help in window area

73Manta72gt · 04-03-2008

Any advice on the best way to repair? I have a flux core welder and a pop-rivit gun. This will be a daily-driver not a show car, but I don't want a water leak

Thanks

azopelnut · 04-03-2008

I can only guess that the rust occured because the rubber moulding failed. You can use POR-15, fiberglass or bondo for a temporary fix but the rubber moulding needs to keep the metal dry so the rusting process is slowed down

guyopel · 04-03-2008

Cut out the rust area and weld in a replacement piece .
I suspect you will find more damage after you remove this section . HTH Good luck
John

trlmr · 04-03-2008

You will need a tool to cut out the old metal. The only tool that really works good for what you need to do is a die grinder with a cut off wheel. They take quite a bit of air, but you can use a small air compressor if you aren't in a big hurry. I never could get flux core wire to work very good,( too much splatter) but maybe you will have better luck. You are going to have to weld metal back in after you get rid of the cancer. I don't see how bondo or epoxy would fill a hole that size and last for any time at all. Perhaps if you don't want to weld it you could use fiberglass cloth and resin then fill the rough with bondo. Try to leave the curved part of the metal if it is possible when you cut the rust out-it will make the finish work easier. It isn't that hard to do, just don't expect perfection if this is your first repair.

73Manta72gt · 06-17-2008

Some pics of the repair. I burned through the sheet metal on the car 5 or 6 times. I used JB weld putty and bondo to smooth things up a bit.

markandson · 06-17-2008

Originally Posted by 73Manta72gt

Some pics off the repair. I burned through the sheet metal on the car 5 or 6 times. I used JB weld putty and bondo to smooth things up a bit.

Not bad considering what you started with, the real test will be that of time to see if you have paint problems or leaks in the future.

73Manta72gt · 06-17-2008

If I had to do the same job over I think brazing would be a better option than welding. The body on the car is really bad not worth the effort to restore, but it gets good mpg and is fun to drive.

Ooooner · 06-17-2008

Hey Helmut, I've seen that car.. It's not near as bad as you say it is! Go for the restore!

opelspyder · 06-17-2008

Alot of times people think because it is a driver you can get away with half way repairs. These areas matter on any car driven or showed, they have to be fixed right, or to the point where rust will not forn anymore. What you did looks fine, and will be covered by the gasket as well. Don't shortcut repairs, because it is a driver, sometimes it has to be better than show to last longer
Keith

04-03-2008	#3 (permalink)
guyopel Member Join Date: Feb 2003 Location: Duluth,Ga. Posts: 649 Real Name: John Provided Answers: 2	Cut out the rust area and weld in a replacement piece . I suspect you will find more damage after you remove this section . HTH Good luck John __________________ Guyopel I have not failed - I've merely found 10,000 ways that won't work." ---Thomas Edison It's amazing what God lets man get away with when lightning is so cheap. Mark Twain

06-17-2008	#8 (permalink)
Ooooner Moderator Join Date: Mar 2002 Location: Concord, North Carolina Posts: 1,118 Real Name: Roy Bell	Hey Helmut, I've seen that car.. It's not near as bad as you say it is! Go for the restore! __________________ Roy Bell 1973 Opel GT 74 Manta Rallye Concord, North Carolina Carolina Opel Club OMC

06-17-2008	#9 (permalink)
opelspyder Opel Key Master Join Date: Mar 2002 Location: Tennessee Posts: 1,301 Provided Answers: 4	Drivers Alot of times people think because it is a driver you can get away with half way repairs. These areas matter on any car driven or showed, they have to be fixed right, or to the point where rust will not forn anymore. What you did looks fine, and will be covered by the gasket as well. Don't shortcut repairs, because it is a driver, sometimes it has to be better than show to last longer Keith __________________ Questions or comments to the Project: Restoration of a GT series 2 -post here http://www.opelgt.com/forums/opel-gt...eries-2-a.html

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04-03-2008	#4 (permalink)
trlmr Opeler Join Date: Oct 2003 Location: Iowa Posts: 109 Provided Answers: 4	You will need a tool to cut out the old metal. The only tool that really works good for what you need to do is a die grinder with a cut off wheel. They take quite a bit of air, but you can use a small air compressor if you aren't in a big hurry. I never could get flux core wire to work very good,( too much splatter) but maybe you will have better luck. You are going to have to weld metal back in after you get rid of the cancer. I don't see how bondo or epoxy would fill a hole that size and last for any time at all. Perhaps if you don't want to weld it you could use fiberglass cloth and resin then fill the rough with bondo. Try to leave the curved part of the metal if it is possible when you cut the rust out-it will make the finish work easier. It isn't that hard to do, just don't expect perfection if this is your first repair.

06-17-2008	#7 (permalink)
73Manta72gt Member Join Date: Nov 2002 Location: Winston-Salem, NC Posts: 341	If I had to do the same job over I think brazing would be a better option than welding. The body on the car is really bad not worth the effort to restore, but it gets good mpg and is fun to drive.

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