For those that missed it yesterday I smashed my bumper so it looked like this

 

 

But today I've been busy and it now looks like this

 

 

I'll update more on the progress as I go along.....

So after much deliberation between the Impul front and the Stillen front, I have decided to stick with the Stillen,

 

And the car is going in the body shop tomorrow :biggrin:

 

The sprayer owes me some heavy discount for wiring his compressor and spray booth so I'm getting the full car sprayed.

 

I've got a slight bit of rust coming through on a rear arch, and some more above the skirt on the opposite side, So he's going to sort all that out too. And hopefully remove the rear wiper I have to give him a hand stripping and prepping it though so i'll take some photo's of the progress.

 

:hyper:

Got the car stripped out yesterday, surprisingly it didn't take that long, the rear bumper was a bit of a chew on but managed in the end.

 

 

 

 

 

There's some rust at the bottom of the sill on the near side, no holes though yet, although with a solid enough jab it may have gone through, the spray guy said he would grind it back and take all the rust out, and then use fibre glass to build it back up. Is this the best way to do this.

 

also lost a good bit of metal on the rear bumper support at the bottom of the wheel arch. The bolt holding the bumper on at the bottom ended up with a rounded head, I only got the bumper off by pulling bits of rust off around the bolt, I was thinking of just cutting the rust out and then not replacing it. didn't think it would effect the bumper all that much.

 

Any thoughts?

I would think that might need to be cut out and fresh metal welded in, they often rust from the inside out. As you're going to all that trouble I'd make sure it's done right. I'm no expert though!

I would think that might need to be cut out and fresh metal welded in, they often rust from the inside out. As you're going to all that trouble I'd make sure it's done right. I'm no expert though!

 

On which part the sill or the bumper?

 

I thought as long as the rust was cut away and the metal treated with something like this

 

http://www.halfords.com/webapp/wcs/stores/servlet/product_storeId_10001_catalogId_10151_productId_188249_langId_-1_categoryId_165594

 

Then it should be ok.

I was thinking about the sill. It might be worth removing the rear 3 quarter trim inside the car, you should be able to see inside the sills and tell what condition they're in, iirc.

Yeah that's not a bad idea, I'll have a look at that.

So after much deliberation between the Impul front and the Stillen front, I have decided to stick with the Stillen,

 

And the car is going in the body shop tomorrow :biggrin:

 

The sprayer owes me some heavy discount for wiring his compressor and spray booth so I'm getting the full car sprayed.

 

I've got a slight bit of rust coming through on a rear arch, and some more above the skirt on the opposite side, So he's going to sort all that out too. And hopefully remove the rear wiper I have to give him a hand stripping and prepping it though so i'll take some photo's of the progress.

 

:hyper:

 

Good choice. Both the Stillen lip and the Impul bumper are a ton better than that 'orrible Greddy Gracer thing you had. Your car will look a peach when it's done, really looking forward to seeing it with a complimentary front end, something I always thought it needed as the rest of it was so nice!

 

:)

 

There's some rust at the bottom of the sill on the near side, no holes though yet, although with a solid enough jab it may have gone through, the spray guy said he would grind it back and take all the rust out, and then use fibre glass to build it back up. Is this the best way to do this.

 

Dude, that's a complete bodge. He shouldn't really be suggesting that. It's a structural area as it's within 30cm from suspension mounts if it's going to be hidden by a skirt, then all you need to do is to weld a patch. Cut out the cancer and weld in some new metal. Doesn't really need to look nice if it's going to be hidden. Fibreglass repairs on sills? Eeeek! Steer clear.

Dude, that's a complete bodge. He shouldn't really be suggesting that. It's a structural area as it's within 30cm from suspension mounts if it's going to be hidden by a skirt, then all you need to do is to weld a patch. Cut out the cancer and weld in some new metal. Doesn't really need to look nice if it's going to be hidden. Fibreglass repairs on sills? Eeeek! Steer clear.

 

So even if the rust hasn't broke through and there's still solid metal underneath you still think I should steer clear of fiber glass? I thought if there's a hole then yeah fare enough but if it was just surface rust it would be OK. I'm nipping back up the unit today so I'll get some better photos of the rust.

The problem with that is, the rust on your sills will be coming from the inside out, so it needs removing. All the bubbling you see underneath the paint are not just small rust blisters, the rot will have worked its way through from the inside of the sill to the outside thus pushing the paint out in bubbles. If I am totally honest mate, it looks like your sills have had some poor repair work done to them already. It's bubbling above the swage line too and that will be rust that's underneath that will have crept up. Rust is like cancer, it needs completely removing if you're ever to halt its progress.

 

If you cut that section of sill out, it would be pretty manky behind it. Grinding back the surface and fibreglassing it is only masking the problem and will make the rot behind get even worse.

 

You won't be able to view the sill with taking the interior quarter panel out either. It's double skinned, you have an inner and outer portion. If you don't take that rot away now, it could start to affect the inner sill and that's where it starts to get seriously expensive and will effect the structural rigidity.

 

I STRONGLE advise you NOT have that 'ground back and fibreglassed', I am actually surprised it was even suggested by your paint guy.

Edited January 24, 201411 yr by Funkysi

Yeah the rear quarter has been repaired before, I remember LeeJude telling me he stoved it into a bollard I think. It's always looked a little off at certain angles, There was bubbles of rust just above the skirt, it was one of the deciding factors in me getting a full shoot.

 

I'm not sure the paint guy actually had a proper look at it, he was busy rebuilding a galaxy. I know he can weld, he was talking about welding up the rear wiper before he noticed the insulation, so I don't think he's avoiding it, but i'll have a talk with him later.

 

Guessing you don't rate the rust treatment paste either Si?

Rust treatment is fine for small amounts of surface rust; for instance, over paint chips, grazes and scuffs, but yours has worked its way through mate, so rust killer will be useless as the metal has corroded through.

Nightmare, So how much do you think I'd be cutting out? Do you think I'd have to go into the door frame?

 

I don't think the other side looked too bad, I figured it was just because of the dodgy repair.

Nightmare, So how much do you think I'd be cutting out? Do you think I'd have to go into the door frame?

 

I don't think the other side looked too bad, I figured it was just because of the dodgy repair.

 

Well, my take on it it is, it's better to do it first correctly. Sure, grinding back and fibreglassing would 'look' fine, but the rot is still there, so it would come back. I've highlighting the area that would likely need to be removed. I've circled the areas with rust. As you can see, it covers quite an area. Whilst you can cut bits out here and there, you're better off replacing that section and since it'll be covered by a skirt, it doesn't really need to look pretty. But it'll serve its purpose.

 

The ringed area will 100% have come through from the inside out.

Edited January 24, 201411 yr by Funkysi

besides, what happens when some numpty tries to jack the car up on the sill and goes straight through the fibreglass.

 

As Si says, do it properly!

Yeah that's what I thought, I'll post up some more photo's later on after I've spoke to the paint guy.

 

Cheers bud.

Here's a couple more photo's from today.

 

 

 

 

 

 

The sill does feel pretty solid, still sounds hollow. but it's hard to tell how far the filler goes up from the old repair. So that was Dean's (the paint guy) worry about welding it. but he said he'll see what it looks like after he's ground it back. If it needs welding then it'll just cost a little more.

Either way he seemed pretty confident he'll be able to sort it.

 

He'd made a start on the bumper, he's gunna get it primed up before making a start on the shell.

Forgot about the first photo until I posted it. That's the bit where the bottom bolt was on the bumper. He's going to cut all that out and weld a new bit over the hole too, that's gotten worse since the last time I saw it on a lift. Think I need to raise the back up and soften the suspension a bit, the wheels been rubbing on the guard for the fuel cap pipe too.

It WILL need welding dude. That rust has come from the inside out. Grinding will NOT remove it. The back of the other sill will need doing too. What's happening to that is what's happened to your rear sections. They rusted from the inside out. Putting stuff over the top of that will do nothing other than cover it.

Yeah dude that's what I'm prepared for, I just think He's a little optimistic. I'll keep the thread updated with the progress I'm guessing it's going to be a couple of weeks.

Got a couple more photo's of the front bumper in primer, it's looking very nice.

 

 

 

Will probably be another week before I can start with the rebuild.

Couple more photo's of the progress.

 

 

 

 

 

few more

 

 

 

 

 

and more...

 

 

 

 

 

 

They're obviously not in order.

 

It's hopefully going into paint next week, but I'm in Holland next weekend :biggrin: So it'll be another two weeks before I can make a start rebuilding. The weather is so nice today, I haven't driven it for weeks, really missing it. :(

More pics!