A little something to keep me busy

[Tractor Dave]

The tank had a coat of Bilt Zinc then two coats of Bilt epoxy. I don't think it will rust again for a while.


The front crossmember was rusty and needed a clean.


It got a coat of zinc and then epoxy.


Then this evening I spent a couple of hours under the car again. I'm getting there slowly but it's really hard work with lots of nooks and crannies.




Still a bit to go on this bit.


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[steve briance]

You are probably not in the right phase of the project now as its mostly built up but, mobile grit blasting was my revelation of this year.

My other project car (saab 99) had engine bay and underside blasted back to bare metal and it cost £375. It took the guy about 2.5hours including tea breaks. The guys trailer mount compressor was a 4L diesel and It was mighty impressive, all nooks/crannies/corners were properly rust free.

Took me longer to clean the grit out of places it shouldn't have been!

Ive previously used a spot blaster with reasonable results - it may be more appropriate for your project and with a good air supply on hand, it would get some sort of cleaning and, make a good key for epoxy right in the corners.

Pic is the spot blaster doing a job on some deep rust pitting.

[Tractor Dave]

Hi Steve
That a great job. Trouble with Audi's of this age is the very thick rubber underseal. The sandblaster tends just to bounce off. The other problem is the mess it makes and I don't fancy that in my garage
Wire wheel is doing a good job. Just takes time and effort and of course a few wire brushes.

[Tractor Dave]

Before putting the brace bar back on I needed to attend to a leaking pipe that goes to the oil cooler for the pas fluid.
It's a pig to get at.


Deep in there. The leak is at the other end. The hose had a split in it.


New Gates oil hose.


Unfortunately someone used red hydraulic oil so everything will need flushing with the proper Green mineral oil.


It's was difficult getting the new pipe back on but after a bit of cursing and cut hands, it's done.


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[steve briance]

You are spot on re the mess - grit gets EVERYWHERE! I made a dolly to get
The saab outside and it was done on the driveway in June...there is still grit turning up today!

Have you tried Clean and strip polydiscs? They are really good at prepping the bare steel once wire brush has pulled off the rubber coating.

They get the metal fairly 'bright' but without removing material like an oxide disc. They are available in various grits - 80grit is a great key surface.

[Tractor Dave]

I did try a poly disc and it only lasted 5 minutes

[steve briance]

Thats odd. I took my entire shell to bare metal with 5 discs. Thats on paint only but did a good job. They would clog up though if used on any sort of underseal.

[Tractor Dave]

What brand were they? Maybe I need to try again

[steve briance]

https://www.ebay.co.uk/itm/284268233...mis&media=COPY

Nothing particular special or expensive. I do think applying too much pressure can wear them out and, i used the face rather than the edge - it is a bigger area and spreads pressure on the metal and disc. Thats less important on the underside but up top, you can create soft grooves in metal using the edges my bodyshop informed me of this

[Tractor Dave]

Cheers. Will give them another go at some point.

[steve briance]

[Tractor Dave]

I got the car ready for the welding work today. Battery disconnected, ecu removed, abs ecu removed.
I had to make some abs cable holders as the ones on the chassis had rusted through and they are nla.


I copied the pattern from a front S2 bracket.


Just need to make two more now.


I cut the first rot out. This gave me a better view of some of the hidden rust. Crikey!







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[K Simmonds]

That has got to be the rustiest C4 I've seen by a considerable margin!

Your theory regarding it be used in/near salt water would explain it, the only other thing that could cause such bad corrosion is poorly repaired accident damage but given that it seems to be everywhere I doubt that's the case.

The spare wheel well is seriously bonded to the body, I tried to remove one from a car I broke in the past and gave up, that's not to say it's impossible.

[Tractor Dave]

Thanks Kit. No sign of accidents anywhere which is good. I suspect salt water dipping on a regular basis

[Tractor Dave]

So I got creative to get into those nooks and crannies.





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