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BigJimnyMeet (North) 2024 (12 Jan 2024)


BigJimnyMeet 2024

14th July 2024
Parkwood Nr. Leeds

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rust behind headlights!

  • Justin83
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16 Jun 2017 06:39 #182084 by Justin83
rust behind headlights! was created by Justin83
hi all, so I noticed some rust behind the headlights, I'm gonna have them out today and underseal after a wire brush attack. how do I get the headlight motor off, it twists and becomes loose but doesn't want to pop out?

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  • Justin83
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16 Jun 2017 08:20 #182088 by Justin83
Replied by Justin83 on topic rust behind headlights!
It was just me being stupid, the plug comes off lol.... The mount of rust behind the drivers headlight was rediculous, the wing nut has seperated and there are holes around the headlight lug, for a newer car it's hardly believable.... Rusts like a 1980's escort.
I've wire brushed, hoovered and hammerited it for now but I feel that front corner needs alot of welding soon....
Mines an 06 so check behind your headlights people.

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16 Jun 2017 09:19 #182093 by 2013gary
Replied by 2013gary on topic rust behind headlights!
How strange, mine's a 2000 and there isn't any rust behind the headlights at all. Was your JImny ever by chance living in Scotland?

Gary

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  • ZukracerV6
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16 Jun 2017 09:41 #182095 by ZukracerV6
Replied by ZukracerV6 on topic rust behind headlights!
My 1999 Jimny failed an MOT because of rust behind the headlights and around the body mounts. Sounds a common issue!

Check around the front body/wing mounts behind the headlight!

Sam

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  • Justin83
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16 Jun 2017 14:38 #182102 by Justin83
Replied by Justin83 on topic rust behind headlights!
Don't know if it's been up there, I bought it from Essex and it now lives in kent... At 60k miles I wouldn't expect it... My old 1999 Audi S3 had zero structural rust..
That's why I like bikes, steel is crap!-)

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16 Jun 2017 18:27 #182113 by jackonlyjack
Attachments:

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  • ZukracerV6
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16 Jun 2017 19:36 #182119 by ZukracerV6
Replied by ZukracerV6 on topic rust behind headlights!
That's exactly where my one failed the mot!

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17 Jun 2017 06:27 #182127 by Keithy
Replied by Keithy on topic rust behind headlights!
After just about welding every part of the silver jimny I've noticed a few things.

check the rear footwell....it would appear the welding robot at suzuki forgets to weld the seam and if it gets footfall it cracks the underseal allowing it to rot....underneath on that seam they forgot to rust-proof it.

B post bulkhead usually has 2 areas of rust....through 2 layers extending into the box section.

rear floor rust protection is ineffective to say the least.

Behind the headlights is a joke :D


A fiddly fun job

In my case I concluded that they want it to rot which makes sense for them financially!

If I could afford a new one I would remove the body and clean all the suzuki rubberised rust trapping material off it.
Chassis could do with protection internally.....I'm a fan of waxoyl for internal cavities on cars so a chassis clean etch prime and 2k paint is on my list with lots of waxoyl.

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  • rappey
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18 Jun 2017 16:49 #182166 by rappey
Replied by rappey on topic rust behind headlights!
nice repair job you have done there Keithy. Something i will have to tackle soon !
Bad design.. I noticed when it rains the water always runs all over behind the headlight... bonnet not really effective at keeping it covered...

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  • mickt
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18 Jun 2017 18:24 #182173 by mickt
Replied by mickt on topic rust behind headlights!
There are a lot more rust traps on these. Check the forums history for the sad tales of woe!

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18 Jun 2017 20:59 #182177 by Keithy
Replied by Keithy on topic rust behind headlights!
I still have the template if yours is missing....only paper so cheap to post.....just a hammer and a vise needed.....one piece of 52mm dia pipe to shape one part.....doddle.

£188 from Martin which to be fair is reasonable but if the landing panel is fine....

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18 Jun 2017 21:00 #182178 by Keithy
Replied by Keithy on topic rust behind headlights!

mickt wrote: There are a lot more rust traps on these. Check the forums history for the sad tales of woe!

Aint that the truth.....designed to fail!!!

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