Rust in the front apron, opinions sought

[joebarthlow]

Anticipating a small rust repair in my front apron, I ended up digging out a trench of rust and bondo. I dug out the soft spots. Looks like I'll need to enlist a pro to cut and weld some metal. Looking for opinions... Do you think I can cut that bottom half of the apron off (above the lip) and weld in a like salvaged piece from another 2002, or should I replace the whole front clip?

 

The metal above and below the trenches seems solid. the rust color you see on the unscraped surface is actually original SiennaBraun.

 

It's a '74 base model, thanks for your input.

Edited December 17, 2022 by joebarthlow

[Mike Self]

Were it mine (and I had one that looked about like yours, after 30 Ohio winters) and theres no damage higher up on the front panel, I'd find an unrusted nose that's been whacked higher up, and cut the relevant sheet metal out to weld into your car. 

 

Rhinoplasty on an '02 isn't a trivial task, and from comments that have been posted, the replacement noses are not only expensive, but require some work to fit properly.  

 

And since all the rust holes seem to be on a flat panel between the upper bulge and lower lip, you might be able to fabricate some patch panels without having to find a donor nose.

 

That rust out is caused by the pocket formed where the outer nose panel meets the lower edge of the radiator support.  The factory didn't do a good job of painting down there, and made the drain holes way too small.  So when you repair, enlarge the drain holes on the radiator support's trailing edge to at least nickel size.  And rustproof the heck out of that seam once the patch is welded in...

 

mike

[joebarthlow]

4 minutes ago, Mike Self said:

Were it mine (and I had one that looked about like yours, after 30 Ohio winters) and theres no damage higher up on the front panel, I'd find an unrusted nose that's been whacked higher up, and cut the relevant sheet metal out to weld into your car. 

 

Rhinoplasty on an '02 isn't a trivial task, and from comments that have been posted, the replacement noses are not only expensive, but require some work to fit properly.  

 

And since all the rust holes seem to be on a flat panel between the upper bulge and lower lip, you might be able to fabricate some patch panels without having to find a donor nose.

 

That rust out is caused by the pocket formed where the outer nose panel meets the lower edge of the radiator support.  The factory didn't do a good job of painting down there, and made the drain holes way too small.  So when you repair, enlarge the drain holes on the radiator support's trailing edge to at least nickel size.  And rustproof the heck out of that seam once the patch is welded in...

 

mike

 

your idea was my first thought. the metal above and below the trenches seems solid. thanks

[AceAndrew]

I'm with Mike.  However, it might be a bit of a search, as that is a common corrosion spot.... so a core may have similar issues.

 

Maybe a new nose, but just cut the lower section and do some fiddling.

 

Glad you're tackling it head on, even if unpleasant.  I know more than one 02 owner who is living in denial by not looking at that area.

[doog]

There's this option:

 

(02 models) Front Panel >73 Lower Repair Section (J) – Jaymic BMW Parts

WWW.JAYMIC.COM

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1502, 1602, 2002, 2002Auto, 2002Tii, 2002Turbo, 1600/2002 Cabriolet, 2000/2002 Touring

 

[billw]

Here are some shots of mine, yours is a little worse off.  The front clips were expensive so I went this route (I had a local body and paint guy do this).  bill

[joebarthlow]

27 minutes ago, billw said:

Here are some shots of mine, yours is a little worse off.  The front clips were expensive so I went this route (I had a local body and paint guy do this).  bill

 

that looks nice!

 

27 minutes ago, billw said: