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Welding patches to repair rust

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24 Mar 2019 13:14 #205003 by RogersJimmy
2001 Jimny

There are two areas of rust in the floor of my Jimny that the MOT tester brought to my attention but passed it anyway. So I thought it best to fix them before the next test.

The attached photos show the areas arrowed - next to the front subframe mounting and at the front of the sill.

Subframe: to avoid having remove the mounting, can this area be accessed and a patch welded inside the car by removing the carpet?

Sill: the rust is behind and beside what I presume is a stiffening bracket that I shall have to cut off to patch the rust. Can I get away with not making a new stiffener here?

Thanks in advance for the benefit of your combined experience with rusty Jimnys!
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24 Mar 2019 18:50 #205009 by jackonlyjack
subframe.No access from inside unless you cut the floor out above
sill.Just cut the rust out weld the floor up first then rebuild the strengthener

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13 Apr 2019 15:33 - 13 Apr 2019 15:35 #206004 by Bosanek
After all the welding is finished, it is of paramount importance to perform the following:
1. Apply an epoxy based primer paint over the bare metal, including the welds;
2. Seal all the welds with a polyurethane seam sealer compound;
3. Apply a non-porous finishing coating of your choice (paint, bitumen, etc.) over the primer paint and over the sealant;
4. Apply wax over layer #3.

Seam sealing compounds are usually available in tubes for uses in a calking gun.


It would be ideal if all the above could be applied from both sides of the welded sheet.
Last edit: 13 Apr 2019 15:35 by Bosanek.
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