Fixing some rust on the Metro

[MetroMPG]

What.. you're supposed to be able to see the puddle??

(PS: That's me critiquing MY welding skillz, not Daox's.)

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Pros: structural integrity is returning, and you're drastically extending the car's life span!

Cons: the car is getting heavier! MPG's, oh no!

[Daox]

A small update. Started filling up the hole. As you can see there is more to cut out still.

I also rust converted and encapsulated everything I could. The converter requires 48 hours before topcoating! So, progress is slowwww.





In the mean time I'm driving my uncle's 98 Volvo S70 2.4L turbo. This car is pretty much the exact opposite of the Metro haha.

[MetroMPG]

Do you think the rust started in the usual location (water getting in the cowl drain in the floor behind the front tire, then migrating back through the rocker? That doesn't really explain why they get so bad in the middle (f to r) of the rocker though.

[user removed]

Middle of the rocker would be where you get the most damage from road debris. Add salt and you have the recipe for Swiss cheese.

regards
mech

[MetroMPG]

I wondered about that.

But all the serious rust I've seen in these cars so far has been from the inside out.

[Daox]

I think some of it is from water and salt getting up in the drain. I think that is the rust you see in the last picture. However, I think Old Mech is right about the mid rocker rust. There aren't really any holes it could get up in there and rust as far as I know. So, it must just be chipped paint and salt.

[user removed]

Originally Posted by MetroMPG

I wondered about that.

But all the serious rust I've seen in these cars so far has been from the inside out.

The instant the integrity is lost to the smallest hole it starts rusting like crazy. Like I posted earlier, seen 6 inch diameter holes on 6 month old cars, rear of front wheel house, in the lower fender where they put no paint or primer, early 70s very sloppy production, one winters weather, New York state license plate on a Buick.

regards
mech

[Daox]

I got a little more done over this weekend... then I ran out of welding gas.





In addition to the rust encapsulator I'm using, I also picked up a can of this rustoleum rusty metal primer. I'm spraying it everywhere I can't get at with the encapsulator (which I'm applying with a brush). We'll see how it holds up.

[cRiPpLe_rOoStEr]

It seems really labor-intensive, but nowadays that no-frills economy cars are not so easily available in America it sounds perfectly justifiable.

[Daox]

It is very time intensive. I'm just not wanting to spend cash on a different car right now. I'd be concerned going through another winter with as much degradation happened in the past year, so the option is to fix it. The price is low as its just metal, primer and paint.