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Detour rust repair before spare tire well replacement


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Buy a BMW it's fun they say....even if you are totally comfortable with welding you will get more so... now that this little detour is finished I can proceed

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'67 Derby Grey VW Beetle

'76 Inka BMW 2002

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Those detours are rough! Going through that myself.

 

Looking good VWscott!

 

Jason

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1973 2002tii (2764167), Baikal, sunroof, A/C, 5spd OD, 3.91 LSD, etc. Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   --> If you need an Alpina A4 tuning manual, PM me!

 

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27 minutes ago, JsnPpp said:

Those detours are rough! Going through that myself.

 

Looking good VWscott!

 

Jason

A breif overview of the "detours" over the past month.  It is part of the process. 

 

 

Bracket for my E85 sensor.

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Fire supression

 

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Floors and tabs. 

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Seats

 

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IMG_5303.jpeg

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"Goosed" 1975 BMW 2002

 

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That rust around the gas tank opening is the result of using a foam seal between tank and body.  Suggest using strip caulk--or at lest closed cell foam strips--when you reinstall the gas tank to prevent it from happening again. 

 

I caught that on my car years ago when I had to remove the gas tank to repair a hole from a kicked up piece of metal puncturing the tank.  Scraped all the rust, used rust-inhibiting paint and re-sealed with strip caulk.  No problems since...

 

mike

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'69 Nevada sunroof-Wolfgang-bought new
'73 Sahara sunroof-Ludwig-since '78
'91 Brillantrot 318is sunroof-Georg Friederich 
Fiat Topolini (Benito & Luigi), Renault 4CVs (Anatole, Lucky Pierre, Brigette) & Kermit, the Bugeye Sprite

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@VWScott, I think you said yours is a 76, right? I think I see a c channel brace in the underside pic. Did you replicate that somehow? I think I may need to do the same thing. I just started the passenger floor. I am not sure if this detour, the tire well, or an outer sill patch is next. 

Edited by popovm
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19 hours ago, VWScott said:

little detour

I guess I'm headed down the same road.

I bought the TIG and need to practice ahead of using it in anger. I haven't welded since Oxy/Acetylene and stick in metal shop in high school 😮  

F2F97D47-84DA-4E3C-AB80-B17B3BFFE28F_1_105_c.thumb.jpeg.e5dfda2ffa8fae8da231bb9542443e0e.jpeg

Edited by JQ02
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1976 2002 - Segundo

1936 Ford pickup hotrod, 2010 Honda Ridgeline

Segundo blog

Paoli (PA) Car Show - Oct 5, 2024

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38 minutes ago, popovm said:

@VWScott, I think you said yours is a 76, right? I think I see a c channel brace in the underside pic. Did you replicate that somehow? I think I may need to do the same thing. I just started the passenger floor. I am not sure if this detour, the tire well, or an outer sill patch is next. 

Yes there was a brace. It was totally rusted out. I cut out the remains and made a box style beam and painted the inside of it and welded it to the rump of the original. I then spot welded the brace to the top piece. It's stiff as a board now and rot free. Not pretty but it's the trunk well hidden and I'm not building a concourse car anyway.

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'67 Derby Grey VW Beetle

'76 Inka BMW 2002

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14 minutes ago, JQ02 said:

I guess I'm headed down the same road.

I bought the TIG and need to practice ahead of using it in anger. I haven't welded since Oxy/Acetylene and stick in metal shop in high school 😮  

F2F97D47-84DA-4E3C-AB80-B17B3BFFE28F_1_105_c.thumb.jpeg.e5dfda2ffa8fae8da231bb9542443e0e.jpeg

It's an easy fix. I used MiG with argon/co2

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'67 Derby Grey VW Beetle

'76 Inka BMW 2002

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1 hour ago, Mike Self said:

That rust around the gas tank opening is the result of using a foam seal between tank and body.  Suggest using strip caulk--or at lest closed cell foam strips--when you reinstall the gas tank to prevent it from happening again. 

 

I caught that on my car years ago when I had to remove the gas tank to repair a hole from a kicked up piece of metal puncturing the tank.  Scraped all the rust, used rust-inhibiting paint and re-sealed with strip caulk.  No problems since...

 

mike

Mike I was thinking of using D channel rubber seal. The same that I used on lower rocker trim since I have about 25 feet of it.

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'67 Derby Grey VW Beetle

'76 Inka BMW 2002

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27 minutes ago, VWScott said:

Mike I was thinking of using D channel rubber seal. The same that I used on lower rocker trim since I have about 25 feet of it.

That should work so long as the rubber channel is (1) on a smooth surface (2) will compress properly when the tank is bolted down so that there aren't gaps between the hold-down bolts and (3) you make sure the paint is fully cured so the rubber doesn't pull the paint up after you install it.

 

mike

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'69 Nevada sunroof-Wolfgang-bought new
'73 Sahara sunroof-Ludwig-since '78
'91 Brillantrot 318is sunroof-Georg Friederich 
Fiat Topolini (Benito & Luigi), Renault 4CVs (Anatole, Lucky Pierre, Brigette) & Kermit, the Bugeye Sprite

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  • 2 weeks later...
On 3/12/2024 at 3:10 PM, JQ02 said:

I guess I'm headed down the same road.

I bought the TIG and need to practice ahead of using it in anger. I haven't welded since Oxy/Acetylene and stick in metal shop in high school 😮  

F2F97D47-84DA-4E3C-AB80-B17B3BFFE28F_1_105_c.thumb.jpeg.e5dfda2ffa8fae8da231bb9542443e0e.jpeg

Tig is sexy that is for sure.  Lucky you can stand in the hole and modulate a pedal (if you have one).  I am starting out using my tig ( I am too embarrassed of the chewing gum welds, but if you ask nicely I will share) and  I am considering a torch with the ability to modulate the amperage built in, as in the tight areas where I may want to tig, it is unlikely that I can modulate a pedal at the same time. 

 

Also "Cold Welding" which is essentially a single shot pulsed tig welder looks interesting.   For short pulses I use my Mig, and believe it or not I use flux core for a lot of the floor, as it has that gummy brown glue on everything that begins to work itself out of the metal every time something gets hot. 

 

I have a proper gas setup for tidy new stuff.  I got my Lincoln SP125 plus over 25 years ago and it has never let me down(touch wood). What makes it special is that the dials are variable(that is the "Plus" part), which means I can really dial in the heat and wire feed for delicate thin stuff (Just like me LOL :) ) 

 

 

 

 

 

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"Goosed" 1975 BMW 2002

 

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On 3/12/2024 at 3:10 PM, JQ02 said:

I guess I'm headed down the same road.

I bought the TIG and need to practice ahead of using it in anger. I haven't welded since Oxy/Acetylene and stick in metal shop in high school 😮  

 

 

 

Her is a link to some home grown amperage adjusters.  He seems like a nice guy.  I may just pick one up. 

 

HOTLIGHTSWELDING.COM

hOTLIGHTS WELDING TIG WELDING AMPERAGE CONTROLLERS

 

 

 

 

 

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"Goosed" 1975 BMW 2002

 

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