Classic Ford Forum
Classic Ford Forum
Home | ONLINE SHOP | Profile | Active Topics | Members | Search | FAQ
Username:
Password:
Save Password
Forgot your Password?



 All Forums
 Ford Escort
 Body Shell / Paint / Panel
 Firewall rust repair
 Forum Locked  Topic Locked
 Printer Friendly
Author Previous Topic Topic Next Topic  

Escortpower
Master

Australia

927 Posts

Posted - 03/06/2008 :  18:50:48  Show Profile  Click to see Escortpower's MSN Messenger address
This is one that most Escort owners will have covered, if not..I'm sure they will in the not too distant future. I have removed the heater bubble from my car to assess the rust in the firewall. Was a fairly simple job to remove and it came out quite neatly.



I now have a slightly larger problem. I have removed the rusted section of the firewall with a panel saw (cut through it like a hot knife in butter) but I am still wondering what the best way to repair it is. I will use new 0.8mm plate and shape it, but do I lap weld underneath, or butt weld, or lap weld over the top??? And what sort of prep should I do? Is sandblasting the area necessary?

I will take some pictures and post them tomorrow to show where I cut it and the damaged section. Any thoughts??
I don't usually do panel work but it's hard to get good help these days...........

Regards,
Craig.


Light travels faster than sound. This is why some people appear bright until you hear them speak.

Duane
Master

Australia

683 Posts

Posted - 03/06/2008 :  19:30:27  Show Profile
Because of where it is I would just overlap by like 1 or 2mm just to stop the welder blowing holes and making the job bigger than necessary. Make the overlap on the inside of the car but weld from under the bonnet and you should be able to make the weld good enough to grind it back and shape it to look good. It might need some bog over the top but preferably not.
Go to Top of Page

whooligan
Guru

Australia
SUPPORTER
2908 Posts

Posted - 03/06/2008 :  19:33:56  Show Profile
.....urrrrm, where's the rust? Looks alright to me.

Mk 1 GT V6 Capri
Perana V8 Replica
Mk 3 Capri project
Mk 2 RS2000 2dr (x2)
Zetec Escort
Go to Top of Page

escortinadriver
Master

Australia
SUPPORTER
1275 Posts

Posted - 03/06/2008 :  20:39:43  Show Profile  Click to see escortinadriver's MSN Messenger address
I agree with Glenn...

What rust???

Must be one of the cleanest heater areas I've seen...

Shaun

'If I'd asked what people had wanted, they'd have said faster horses....' Henry Ford
Go to Top of Page

gmgeeman
Scholar

Australia

243 Posts

Posted - 04/06/2008 :  18:34:42  Show Profile
Wow that is really bad. I only wish mine had been that bad
Go to Top of Page

Escortpower
Master

Australia

927 Posts

Posted - 04/06/2008 :  19:42:00  Show Profile  Click to see Escortpower's MSN Messenger address
Geez, you blokes really know how to kick a man when he's down.

Seriously, it was bad enough to repair and while I had the motor out for a changover it was the ideal oppurtunity. Also, if I fix this now it wont turn into frankensteins monster in a few years. Some of my early Escorts were Fred Flinstone cars.

Heres a few pics of the pieces I removed and the hole as it now is.







So what my question is, is how should I go about replacing the rusty bits. Should I make a panel the same as what I cut out and butt weld it in or should I make it larger and come from underneath etc...??

Uncharted territory for me here so all help appreciated.

Regards,
Craig.

Light travels faster than sound. This is why some people appear bright until you hear them speak.
Go to Top of Page

Paul Dunstan
Guru

Australia
SUPPORTER
2246 Posts

Posted - 04/06/2008 :  22:16:50  Show Profile  Click to see Paul Dunstan's MSN Messenger address
Find a good section and butt weld the lip (double skin) and place the fire wall section just inside and lap weld it as above.

That's how mine was done (see pic). When it's finished the lip hides the bulk of the repair from sight anyhow. The most you have to do is add a little filler to bring up the lap welded section if you want to get picky





Finished



Cheers

Paul

Edited by - Paul Dunstan on 04/06/2008 22:17:40
Go to Top of Page

binalong
Master

Australia

601 Posts

Posted - 04/06/2008 :  22:56:28  Show Profile
after you weld, paint over with "POR15" rust preventive paint it will out last the rest of the car

binalong
Go to Top of Page

jpayne
Scholar

252 Posts

Posted - 05/06/2008 :  04:21:37  Show Profile
seam weld a new lower and top section to the heater surround flat and the bulkhead respectively. Then join the two parts together with a series of spot weld. Drill through the top sheet and clamp together and plug fill the hole. makes it look factory. then grind the seam welds smooth seam seal the rear of the repair, from underneath and nobody will be the wiser. Car lloks relatively rust free.

Good luck with it.
Cheers,
JP
Go to Top of Page

PeterM
Master

769 Posts

Posted - 08/06/2008 :  09:26:32  Show Profile
I'd leave the cutout hole there and not repatch it. Under full throttle you might just have enough room the put your hand through to find the dizzy to get a bit more advance....!
Go to Top of Page

Escortpower
Master

Australia

927 Posts

Posted - 22/07/2008 :  20:27:25  Show Profile  Click to see Escortpower's MSN Messenger address
Well, here's the work so far.













Now I just gotta work out whether or not to seam weld the lip or drill and plug weld it. That is my job for tomorrow.

Regards,
Craig.

Light travels faster than sound. This is why some people appear bright until you hear them speak.
Go to Top of Page

Escortpower
Master

Australia

927 Posts

Posted - 28/07/2008 :  21:13:09  Show Profile  Click to see Escortpower's MSN Messenger address
Ok, welding is now finished. So... what comes next? Do I put body filler on the bare metal or does it need to be treated first? It only needs a little to smooth out some of the grind marks etc. If I use POR15 do you put that on beforehand ???

Please help. I am lost now.

Regards,
Craig.

Light travels faster than sound. This is why some people appear bright until you hear them speak.
Go to Top of Page

binalong
Master

Australia

601 Posts

Posted - 29/07/2008 :  09:44:51  Show Profile
once the welding is finished, do all the grinding and sanding, once it is ready to paint, go over with "POR15" let dry, then fill with bog if needed, sand, undercoat , paint and then spray with "TECTOIL" will last longer than the rest of the car "POR15" can be used over ANY bare metal that has been scraped or sanded to remove flaky bits ...it really is TOP STUFF on bare metal

binalong

Edited by - binalong on 29/07/2008 09:48:14
Go to Top of Page
  Previous Topic Topic Next Topic  
 Forum Locked  Topic Locked
 Printer Friendly
Jump To:
Classic Ford Forum © 2003 Bud DaDude Web Productions Go To Top Of Page
Powered By: Snitz Forums 2000 Version 3.4.03