Rust

[steviet_1988]

Hi guys

I had some spare time at the weekend so i though i would jack up the gtx and see what condition the underneath of the car is in. Unfortunately I found some rot. Thereso some on the passenger side sill and a on the passenger floor panel but the worst bit is just in front of the driver's side rear wheel. Are these common places where they rust and has anyone had this repaired? My plans were to get the car back on the road this summer but that may not happen now. Where's the best place to get panels for it?

Thanks for any help
Stephen

[GTXTRA]

Check rocco grotto project thread/search for Rust Republic on here.

[the edmundator]

Mk2 rust spots are generally:
- anywhere under the body-kit (if fitted),
- inner rear wheel arch around where the fuel filler attaches on the other side,
- Boot lid around the number plate lights
- rear panel near the inner upper corners on the rear lights
- lower rear corners
- quite frequently along the lower edge of the rear side windows, which causes rust inside the leading edge of the rear wheel arch as water drips down
- lower door edges
- around side repeaters on front wings
- underside of bonnet
- front panel behind plastic trim

So, yes, I'd say your car has rust in a common place. Fairly easily repaired by someone suitably skilled.

For panels:
VW Classic Parts (VW official supply, Germany)
VW Heritage, Classic VW (UK)

[Nate]

Depending how widespread the rot is, most of what you mention should be repairable to a good standard using just flat sheet

[steviet_1988]

I will check that out gtxtra, thanks. I took the sideskirts off today to get a better idea how bad it is. The rot seems to be just on the sills and hopefully isnt structural. The rear arches will need some attention too but would they need to be done for an mot? I also noticed the fuel filler pipe is stainless steel, is this standard?

Thanks again
Stephen

[Village Idiots]

Sills are structural and MOTable. Is it just surface rust or more serious?
What is the area round the rear beam mounts like, this is an area known for rust and is structural?
Stainless is not standard for fuel filler and is good news as these are known for rusting and rotting, leading to rust getting into the tank and causing running problems.

[Nate]

Arches mostly aren't testable as part of the cars structure, but they can fail for sharp edges (just covering with tape is sufficient to get a pass in this case)

[steviet_1988]

It's more serious than surface rust. I can poke holes in it. The worst bit is in front of the driver's side rear wheel where there is a fuel pump/filter. I have someone coming to look at it as i dont weld, hopefully it won't cost too much to repair. The arches are covered by the bodykit so i might just try and get it roadworthy then sort them at a later point. I want to try and make this years annual meet at cosford.

[james butler]

when i used to weld cars my company charged £5 per square inch of hole so you can imagine how that would mount up.
alternatively some auto welders will charge by the hour or job so would be a good idea to do some prep work before calling the pros in.
for example removing the carpets and interior in the areas needing welding is a good idea to make the welders life easier and shorten the time they have to spend at your cost removing it for you especially bodykits that will be brittle with old age and they wont be gentle in taking them off as they wont have time.

[duggers]

as James said, do the stripping of trim, insulation, wheel arch liners etc yourself and it will reduce the time and make the job easier and cheaper.
Rear axle mount area is very common but repair parts are not too expensive. Golf Mk1 repair sections will do axle mounts if needed but also as stated a good welder can use flat sheet and weld in sill repairs.

[steviet_1988]

Thanks james and duggers. The car is already stripped out on the inside as i wire brushed and then applied a few coats of hammerite to the interior floorpan. I've removed the side skirts but not the arch covers yet. I do have pictures of the rot but i can't remember how to upload them on here. If the rear axle mounts need welded will i have to remove the rear axle?

[james butler]

in short yes mate because the entire area is structural and needs to be one solid piece of steel attached to the chassis.
speak to the person doing the welding for you to see if it will need removing or not.

i upload pictures by putting them on photo bucket and then copy and pasting the image link from photobucket onto here.

[Nate]

If you are paying someone, make sure you know what they are going to do before they start. Just sticking a bit of steel over the top of the hole is suffice for an mot pass, so is all that a lot of people want done. Aside from not looking very good, this sort of repair generally won't last too long, as moisture will get trapped between the 2 bits of steel and it will rust out quite quickly.

Ideally the rot will be cut back to good metal, then a new piece let in and the welds dressed so you can't see its there

[Village Idiots]

If there is any rot around the rear axle mounts, the beam needs to come off and the job done properly. The rot is likely to be more extensive along the sills and box sections round the rear wheel inner wing. New sections are available but great care is needed to fit these as you must get the mounts for the rear axle in the correct location. Look at some of the posts from Rust Republic's restoration work, for example on my MK1 cabriolet (MK2 is the same floor pan)

[steviet_1988]

Driver's side rear sill