Dreaded Rust :(

[Error404]

Stripped the rear end of the CQ to fit my refreshed rear subframe and Torsen diff.
Fuel lines needed replacing, as did the handbrake cables, and by the time i'd got that far i decided i was going to go the whole hog and strip and reseal the whole uderbody with POR15 and new underseal.

Pulled off the passenger side arch liner and found some nasty rust - two patches which have rusted right through
I put my finger through a patch on the front side of the arch, and met the insulation on the other side. Then did the same on the rear side where the bumper bracket and liner screws in. This is one of those times you wish you'd never looked!
Not removed the drivers side liner yet, but fearing the worst.
At least i caught it now and not in a few years when i might need to replace the whole tubs i suppose.









Would love some advice about the best way to sort this and anyone who can help or point me in the direction of someone to talk to.
I guess its a case of cutting the rust out and welding in new plate? What is the technique for this? Any UR boys got any experience i wonder?


Cheers guys
Alex

[Fat Audi 80]

Hi Alex,

That is shocking! I can only assume it has had body repairs, I have never seen or heard of rust like that on these galvanised bodies. (anyone else?)

I would suggest the only way to sort that is cut out and weld new plate in. It should not be THAT expensive. They are only small repairs.

Good luck,

Cheers,

Steve.

[K Simmonds]

I've never seen anything like that on an Coupe before or any Audi after 1988 for that matter. Shocking must have been in the sea or something.

[Error404]

That is shocking!

Tell me about it!! Couldn't believe it when i went straight through
Ironic that i was stripping the car to protect it from this in future!
We'll see what the other sides like, but ihad to deal with a nother dodgy repair when i stripped the front arches last year - rust creeping under the body sealer

At least once i've sorted the rear end i'll know its all fine.
Thinking i'll be treating the inside of the chassis rails with dynax or somthing for good measure.

Anyone know what thickness the panel is on the arch tub??

[GT500]

Now you know why my RS is parked up and I am driving my pub bus whilst the salt is down!
Seen it too many times! yes I can repair it so you would never know... do I enjoy it? NO WAY!!!!!!!!!!!!!!
We should take the councils to court!

[spink]

never seen any bad bits on the rears of coupes but the front inner wings are started to crumble badly on some.My last aby(1993) was bad enough to be able to push my finger through the metal(around the steering tie rod on the drivers side) plus a cq20v i had recently was getting that way.Both cars had spent their lives around inverness but i have also seen early signs of it on southern cars aswell.

[Rusty]

Looks like it's started from the captive threads/bolts where the arch attaches. My front arches have a little bubbling on the leading edge.. hope the rest of the car is OK

[Acidburn]

First time i've ever seen rust like that, sorry to see that alex still at least you caught it early.

[panzerwagen]

Rust on our cars & why it may be happening...

First of all if your are seeing it in the wheel arches it may be that a stone or something else has punched through the galvanized surface and left the area unprotected. Or as mentioned on the thread, the captive nut has started to go south. Any place on these cars that have a hole for access of a screw or bolt and is not protected or the protection has worn away will let Rust start its evil deeds. Be vigilant.

[k.alle]

Would love some advice about the best way to sort this and anyone who can help or point me in the direction of someone to talk to.
I guess its a case of cutting the rust out and welding in new plate? What is the technique for this? Any UR boys got any experience i wonder?


Cheers guys
Alex

Oh, been there done that mate!

But, compared to my S2 you can consider yourself lucky!


This is what met me after rear left quarter rubber trim decided to just fall off

WARNING! HORRIFIC PICTURES BELOW, I WILL NOT BE HELD RESPONSIBLE IF YOU NEED THERAPY AFTER LOOKING AT THESE!! WARNING!












How to fix it? Another S2 Coupe acting as a donor and a very gifted friend:mischeif:








End result though, as new according to me.




It hurts my heart just looking at those pictures again, I feel your grief Error404

[Jamo]

Christ almight!!!!!!

[Skull]

please someone delete this thread

[Error404]

Rob - PM sent

Yeah i think this was caused by a stone that was caught behind the arch liner and rubbed through the protction, et voila.
After i replaced both front arches and cleaned up the rust i found there, there was enough to make me worry. This is pretty nasty, and i'm yet to take off the other rer arch liner, wasn't sure i could handle the result after seeing this lot.

Anyhoo, k.alle your pics makes mine look pretty lol.. it will be sorted and good as new in the end i'm sure

So who's going to be puling off their arch liners to check theirs on Saturday morning???

[panzerwagen]

So Error, tell me how did the rust get there? Gods will?

It had to be something. Dodgy body work? I have had my CQ since 90 and have checked the wheel arches several times through it's life. They look as clean as the day the car was built. Still has the body wax intact inside there too.

[k.alle]

Anyhoo, k.alle your pics makes mine look pretty lol.. it will be sorted and good as new in the end i'm sure

It sure does, doesn't it
Mine did get repaired very thoroughly by a friend of mine under my supervision and also went to the painter and inspected his priming and so on, I would never trust any body shop to do the job properly.

You've got the right spirit though, it's the end result you'll have to concentrate on and just get on with it.
When it's all said and done you'll almost forget that it was ever there

So, good luck