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What is causing this to rust?

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mattsmithadelaide
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2013/06/08 18:02:40 (permalink)
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What is causing this to rust?

Hi,
I have taken off a lot of the sound deadener and found a bit of rust in the passengers footwell over and to the left of the chassis rail. Just wondering what causes this to rust as I'm trying to prevent it happening again.
Cheers!

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12 Replies Related Threads

    Drewdog
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    Re: What is causing this to rust? 2013/06/08 21:50:56 (permalink)
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    Finding the same thing in my shell, a bit worse though......... It looks like the wheel arches have been hit with sand, dirt and wet weather and rusted from the outside in. My bulkheads cactus too and inside the water marks and rust spots match up. Yours look pretty good, maybe weld/ patch smother with rust coat and fresh tar underneath? That and I'm not going to drive mine in the wet again
    Good luck with it, Drew..........
     

    GT Cortina Project "The Ugly Duckling"
    #2
    Paul Dunstan
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    Re: What is causing this to rust? 2013/06/08 21:59:37 (permalink)
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    More often than not its water leaking into the footwell from either a leaking windscreen or (more likely) a rusted section of the bulkhead behind the heater assembly (mounted beneath the plenum in the engine bay).

    Cheers

    Paul
    #3

    mattsmithadelaide
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    Re: What is causing this to rust? 2013/06/08 22:33:42 (permalink)
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    Thanks Drew, same to you mate! I wasn't expecting to find it as there isn't any other rust in the car!
    Cheers Paul, I'll have a further look into the heater plenum tomorrow but there appears to be no rust around that area! I was hoping to paint it this weekend but these things happen! 
    #4
    GeeBeeN
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    Re: What is causing this to rust? 2014/02/01 22:49:20 (permalink)
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    Rust we can see, can be dealt with a variety of readily available chemical treatments, most are safe, some are
    not so safe. Smash Repairers wipe over the bare metal with, (whatever the trade name) a Phosphoric acid and
    water solution, this converts the rust that can't be seen, to a phosphate, when dry apply a primer and continue
    on with the repair. not a safe way to go for amateur painters/repairers.
    Cheers 
    post edited by GeeBeeN - 2014/02/18 23:03:36
    #5
    MK1_Oz
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    Re: What is causing this to rust? 2014/02/02 10:13:29 (permalink)
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    might be worth coating the new surfaces with something like POR-15 just incase (or when) the screen leaks again?
    #6
    Timw
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    Re: What is causing this to rust? 2014/02/04 22:56:30 (permalink)
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    The other possibility is leaking through the seam sealer of the joint at the A pillar which is fed by the gap between the front guard and the body.
    #7
    jpayne
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    Re: What is causing this to rust? 2014/02/05 10:03:02 (permalink)
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    As you can see from the pitting it has been rusting from this side out, and depending onth eother side it might be outside in.
    The sound/body deadner/ carpet was probably the true culprit, water ingress through use, leaking seals, door and windows, heater bubble, split seams etc gets trapped against the steel by the aformentioned stuff and works its magic.
    very common problem for escorts as you know.
    My fear about not cutting it out and welding a new pioece in is it wil keep rusting no matter how many chemicals you add. the steel is already damaged and very suceptible to further rust.
    As I am replacing the exact same part on my Mk1 I know how difficult this part is to make.
    good luck
     
    Justin
    #8
    GeeBeeN
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    Re: What is causing this to rust? 2014/02/18 22:32:42 (permalink)
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    POR, is a great system, hard to implement on a car that you don't want to strip to a bare shell.
    Penetrol, is an oil, that creeps/migrates converting rust as it goes, when dry apply a primer. brush or
    spray on. parts that are rusted through are still treated by replacing weakened areas welding in patches.
     
    The areas, where we can't see the rust, i.e. chassis rails etc, Please list and post the areas where we/you
    cannot see the Rust.  I intend to calculate the internal surface area, of a, say a chassis rail, drill a 2mm hole,
    and inject X mils of Penetrol, with a Suringe. I've a new bare metal guard that i can use to see the area 
    covered by applying, X mils of Penetrol, to this quantity, i will add 30%. My base line.!! as a backup i'm
    adding Electronic Rust Prevention, confident that my Mk2 won't be off to a scrap yard, in the next 37 years.!!!
     
    Cases containing Air Conditioners, on the Gold Coast, salt air, humidity all that stuff, a new 18 story building
    installed ERP, Customer was happy with the air cons performance, 6 months later, Rust, (not happy joyce)
    No one turned on the Electronic Rust Prevention.  … … Made me smile, must be my warped sense of humour.
     
    Cheers Geoff
    post edited by GeeBeeN - 2014/02/18 23:06:29
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    Timw
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    Re: What is causing this to rust? 2014/02/19 19:41:35 (permalink)
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    Another possibility that I have seen is water tracking down the antenna wire at this location.
    #10
    pmartin
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    Re: What is causing this to rust? 2014/02/20 14:10:57 (permalink)
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    Hi guys, here's my ten cents worth! Moisture + oxygen = rust. I am 65 and even I have a few rusty bits!
    Dry the area out as thoroughly as possible, even use a hair dryer or heat gun. descale the rusted area, wire brush etc. make sure you vacuum up any hard to see, left over scrapings and don't use steel wool EVER, it always leaves a near impossible to see residue. Then treat area with Penetrene first, then Penetrol, then prime with an oil based undercoat/primer or even Gal paint and then coat with an oil based enamel. Enamels of this kind definitely keep out moisture far better than water based products. The paint will stick like the proverbial to Penetrol. I am only guessing that the area in question is normally out of sight so a brush will do! (any brushmarks won't matter). I feel confident that if you do the above even if the area even gets wet, not just damp, it will take a couple of years for anything bad to happen again. But as said in an earlier post by a helpful member, if you can, weld in a new patch and then follow the same finishing procedures. Particularly if you suspect the area to be structural in any way.
    And last but not least, and I am sure you are doing this anyway, find out where the waters coming from, Phil
    #11
    Drewdog
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    Re: What is causing this to rust? 2014/02/20 22:21:43 (permalink)
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    I've been following up my welding with a zinc primer and smothering everything with por15. I learned a lot but after months of fabricating and welding I never want to have to do it again. Interested in the electronic units at the moment and am doing a bit of homework on them. Theres a few types with multiple electrodes. Any ideas which are the better units? How many electrodes for an Escort?? and where do they need to be mounted???
    Cheers Drew............
    post edited by Drewdog - 2014/02/20 22:28:23

    GT Cortina Project "The Ugly Duckling"
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    pmartin
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    Re: What is causing this to rust? 2014/02/21 08:09:58 (permalink)
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    Hey drewdog, sounds like you are doing everything possible really to make sure your beautifully arranged collection of nuts, bolts and sheet metal are given every chance of survival. Well done! 
    Electronic rust preventitive units? Well I think if they are as good as they claim, everybody would have one on an old car. But they don't. So is that telling us something? Modern cars are so well made now that we seldom see rust of any kind unless there has been damage to the coatings and not repaired correctly. For example I have a Porsche (sorry!) which came from the factory with a 10 year corrosion guarantee. Galvanised panels are the answer. I have a mate who beach fishes all the time and he has electronic protection fitted, no rust, BUT he also washes/hoses cleans the car after every drive on the beach (old Suzuki 4wd). So does it work? Not really sure...
     
    ps I also have a 65 T Bird, 73 mustang convertible, 66 Mustang coupe and 82 Corvette
    I am waiting on an answer right now on an offer I have put in on a totally original one owner 1600 Capri Mark 1!Rare as...I think?
    #13
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