Ol' Rusty - FB/EK Sedan

Post photos of your pride and joy, or updates on your rebuild!

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Blacky
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Re: Ol' Rusty - FB/EK Sedan

Post by Blacky »

Kudos to the young bloke , good to see he perseveres with a job like that instead of wandering off :thumbsup: :thumbsup:
When you're faced with an unpleasant task that you really don't want to do, sometimes you just have to dig deep down inside and somehow find the patience to wait for someone else to do it for you.


Foundation member #61 of FB/EK Holden club of W.A.
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

repair 1.JPG
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Found a bit of rust passenger side sill in the rear wheel arch. Previously repaired. Cut/ground out the old patch


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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

repair2.JPG
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Made up a template with a bit of aluminum. Decided to have a crack at mig welding. Figured no one will ever see this.


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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
ardiesse
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Re: Ol' Rusty - FB/EK Sedan

Post by ardiesse »

I've got a paper template for this section - I can photocopy it and mail it to you.

(Only just saw your aluminium one. Offer still stands.)

Rob
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

repair25.JPG
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After a couple rounds of weld/ grind with gasless 8mm wire. Couple of blow throughs in both the sill and my patch. Not easy working in this space and getting the MIG torch in all the right places.


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Last edited by funkyscooter on Sun Nov 15, 2020 11:59 am, edited 1 time in total.
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Thanks for the offer Rob. Still on a bit of a trip down memory lane with pictures. But want to document chronologically.


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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

repair3.JPG
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A few more rounds of weld/grind (after stepping away for a week). Dremmel has been my friend in here.


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Scott
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

repair4.JPG
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Finally hit it with some primer. Will leave for now and tackle the other side.


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Scott
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Image
Okay. So not as simple as the passenger side. Noticed a few bubbles in the sill but when I attacked it with my sharpened screw driver it pretty much fell apart. Went to work with the angle grinder to check the inner sill. Looked ok under the car.


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Scott
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

Very tidy. Yes it is a tricky spot. Do yourself a favour and get some gas.


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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Image
Not so great. Lots of little pin holes. Sigh. Did some reading and the outer sill ‘seems’ relatively simple to repair.


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Scott
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

The paint was all that was holding the shape. Usually passenger side is worse.


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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Image
Then I got to the A pillar. Both inner and outer A pillar sections need work, as well as the subframe bracket. There is also a bit of rust in the floor around the A pillar that has been badly patch over.


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Scott
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

It is a big job but the replacement panels help. Inner can possibly be saved? Patch from the inside and paint and protect well.


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getting my FB ute on the road
EK van on rotisserie
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Sill.JPG
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After much hand wringing and read decided to fix this myself. Read somewhere on this forum with regards to welding and body work that it’s only metal, if you make a mistake, cut it out and do it again. Good advice
Ordered new inner and outer sill, inner and outer A pillar section , lower fender repair section, 6mm MIG wire, a regulator, and a D bottle of gas. In for a penny.......


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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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