RUST!

[archieaja]

Hey fellas.

I've always been a buyer of new cars in the past so pulling off trimming wasn't really an option or a necessity for me.

I was (I thought) very conscious of checking for rust when I chose my Perentie but as a newbie I guess it was always going to be the case that something was missed.

I found a decent sized hole in the door jam/firewall that had been (very) badly patched and that patch has also corroded through.

I was hoping someone could give me an idea on what would be the best way of nipping this in the bud. The rest of the vehicle is pretty much completely rust free BTW.

[FFRMAN]

Really the only way is to cut out the rust and weld in new steel, prime/undercoat/paint.

well that my experience anyway

regards
Scott

[Dervish]

Rust in that area is not at all uncommon - mine has some there too. Repair sections for that section of the bulkhead are readily available, I'll pick one up shortly. As Scott says, the only solution is to cut out the rusted steel and weld in a patch - either part or all of the repair panel in your case. Not hard if you can weld, but intimidating if you haven't done it before.

eBay link:
http://www.ebay.com.au/itm/LAND-ROVER-DEFENDER-90-110-BULKHEAD-A-POST-BOTTOM-OUTRIGGER-BRACKET-DA2026N-/371097273568?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item56671f04e0&_uhb=1

[archieaja]

Thanks guys.
Dervish that is exactly the section I was talking about. Correct side too. Would I be best off just cutting out the whole section and replacing it with the one you linked to or should I just cut out the problem area and patch it with a section of the replacement?

Does that even make sense?

As for my welding skills... they sure as hell can't be worse that the guy who did the original patch! Seriously, they hadn't even prepped the metal.

[FFRMAN]

I'd only be cutting out the bad spot, the door struts (for want of a better workd) are an integeral part of the fire wall and add stability to the door structure, less you have to play with it the better - in my opinion