daz1989

Is there any1 out there who has tackled the rust round the front windscreen seal, who maybe could point me in the right direction to repairing the areas as iv removed the windscreen and theres 3 layers where other panels meet.

daz1989

Weepeeps

Mate. You'll need to cut about 20 mm past all the rust on all 3 panels. Try and drill out the spot welds on the flange before you start. When you've removed the offending piece carefully separate all three pieces. I usually take pictures on my phone along the way. Recreate the repair sections using a metal folder and 1 mm zintec sheet. Two pieces of angle in a vice will do the same trick you may need to do some shrinking/stretching (Google making panels by Tony bmw on retrorides) great thread on making stuff like this. When your happy with the fit stitch weld them with a mig ( check out mig welding forum welding thin sheet if you don't know what this is) but basically move around and allow it to cool a lot between welds or it'll warp with the heat. Recreate your flange on the inside by plug welding it make sure the metal is tight together and use a 5/16 drill for the holes. Make sure you get some seam sealer on it when your done before painting. Hope that's a wee bit of help mate

Weepeeps

Oh and for cutting out get some of the really thin 1 mm discs for your angle grinder !