Help needed please please

[caprifan]

...help needed all please....as part of my get it back on the road project on the old Capri, I was expecting a small patch needed on one of the rear chassis rail....on cleaning the other one however I have come across a big problem.....

 

bare in mind this started as a 1cm crack in the rail............its all rusted from behind !!!

 

..I still don't know how far it extends....I'm assuming the whole length of the previous patch but don't know how far the other way as the rail looks good from the top....

 

I need to know if it can be patched without looking like a dogs dinner or do I need a replacement chassis rail ???

 

you can see a previous patch done behind the hole...I have now found that the patch was welded ON TOP of the rusty rail

 

all advice greatfully received as I have done pretty much every thing on my car but nothing like this...........

 

 

 

[flyingbanana]

take measurements and chop it out and get your self down to a metal engineering place and get them to make you a half box section up or buy a new rail and weld it in

[Twinkle]

im confused as that looks original from the spotwelds and the flange to the floorpan! yes it looks plated in the first pic but the rest looks original

[caprifan]

....the whole rail is original apart from the patch you see....what you see in the whole is a strengthening section inside the rail.....

[X-pack-Glyn]

What you should do is get a time machine and go back say....15 years, blast the whole rail in wax oyl via the hole under the rear bumpers, then come back.

 

problem solved mate

[mk2 stu]

ok first off dont panic!

Can you weld? if so cut out the surface steel neatly using a thin metal cutting disc, only remove a neat section of the surface panel, only about 10mm beyond the inner layer of rust.

now using the disc again remove all of the rusted inner section.

Measure up a plate to fit in the cut out area, prime the back of it and then weld it in.

now grind back the welds and then fully prime the section.

The exterior panel now needs to be measured and cut in, try and butt join it as opposed to lap. Weld it up and then grind back, sand it down and coat of primer and your done!v

[caprifan]

....first problem.....can't weld and don't have a welder.....

 

MK2 Stu are you able to do it ?.......how much to do it ? or anyone else ???

 

 

I'm going to cut the patch off to see the extent of the rot

[Doc]

Mate its an easy fix .

 

Like said earlier get a local metal worker to make the chassis rail for you once you take measurements and cut the rot out . Get a mobile car welder to come and sort it .

 

Wont cost the earth just take your time when measuring .