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Baja Forums -:- VW Volkswagen Bug, Baja, Bus, Sandrail and Thing -:- VW Volkswagen & Baja Bug General Discussion -:- Rust Help
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Rust Help
Bug, Baja, Thing and Buggies. Most every thing that will not fit any any other area. See list of other Forums for better topic placement...Volkswagen General Discussion
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navynuke
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Post Post subject: Rust Help
Posted: Mon Oct 13, 2008 02:37 AM
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Ok, stipping the interior of my baja I found some nasty rust around the door mounts.

here is a pic




what is the best way to reinforce this area so the doors are solid? I'm using a 1 piece front end so it dosn't need to be pretty, and the cage is supporting all the major suspension stuff, but the doors are flexy.

and I don't have a welder, and even if I bought one, I'm not very good at it.

any help would be great here guys.

Ken

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locutisj
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Post Post subject: Re: Rust Help
Posted: Tue Oct 14, 2008 12:40 AM
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OUCH!
The one thing I can think of (w/o welding) is to find a piece of metal 1/8 to 1/4 thick and cut to fit the shape from the the top hinge down to the bottom hinge and bolt through the body and added metal. That way you're grabbing the remaining body metal and in a way clamping the door on.

The best way would be to weld in some supports that tie into the cage if possible. I can't see your cage very well so I don't know if that's possible.

I'm just a "back yard fabricator" so may be some real fabricators will pipe in soon with a better solution.


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navynuke
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Post Post subject: Re: Rust Help
Posted: Tue Oct 14, 2008 02:45 AM
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so right now looking at adding some sheet metal, just pounding to shape and welding in, as well as ading a brace from the cage to the hinges.

have a buddy who will help me with it in a week or two if I don't get something else first.

and looking at buying a welder, will a 120v with gas work, or should I pony up and get the 220v?

Ken

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Post Post subject: Re: Rust Help
Posted: Wed Oct 15, 2008 03:32 AM
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I'm thinking to fix this run a piece of 2" wide 1/8th thick metal from the cage, over to the door hinges, and tie both together, so I end up with a ] shape from the roll cage to the door hinges. its about 5.5 inches away from the cage.

does this sound like it would work? and then just replace that rusted out piece by your foot with some thinner metal.

I borrowed a wirefeed welder from someone, and think this might work.

any advice?



you can see the cage to door posts in this pic.

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locutisj
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Post Post subject: Re: Rust Help
Posted: Thu Oct 16, 2008 08:43 PM
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That should do it.
The wire feed welder might burn through the thinner sheet metal so go easy. You may have to "spot" weld with that. I had a few areas where I had to take the same approach because I kept burning through so I just hit it in spots.


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navynuke
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Post Post subject: Re: Rust Help
Posted: Sun Oct 19, 2008 02:00 AM
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well all it needed was a brace at the bottom. the top is as stable as it ever was.

so here's how the fix looks, not pretty, but it works. no more sagging door, and I couldn't knock the thing off with a hammer. lets hope it holds up.



and making a template for the panel


and tacked in. did finish welding it, but no more pics after I got done with it.



any critique of my welding skills is ok, first time I've ever welded anything together.

thanks Ken

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