AX 10E rust rear corners welding

[jsp]

Morning all,

Just wondering how did some of you guys welded this section?

Hard to access rear corner behind the lights common rust area on a AX.

I am restorating it so need some advice of the forum here.

Some pictures from the section that needs to be repaired:

[lexi]

That is going to be lots of cardboard templates and thinking. A bit cut out and welded in where possible to retain profile, then more cut out.
Photo's from before and careful measurement with calipers and a mock drawing. Another car for a reference would be good. Lots of stitch welding and bracing to avoid distortion, then seam weld and cut and grind braces off. That kind of stuff.
There is a great build on a MK 3 Cortina on Retro Rides. I have lost the link but it will give you great method and ideas.

[jsp]

Thanks for your reply,

I was considering cutting it out with a Dremel and refabricate this section.

[jsp]

Step 1 is going on now making separate panels and welding in.

[davie206]

Pain in the arse this was on the ax. I was using a 90amp flux core welder and couldn't get it set right so I bird cropped it as you can see in the pic, then stitch welded over the top of it not shown in pic

Sent from my E5303 using Tapatalk

[lexi]

Yeah, flux core is not good with a cheaper machine and thin panels. Use a copper or ally plate behind the joint.
It will draw heat from the edges and help in getting a puddle and not shooting through.
I find the 4" angle grinder with thin 1mm disc is as good as anything for cutting.......if you can get in. I have every tool for cutting. Air saw, reciprocating saw, plasma cutter, jig saw, nibbler. But if I only had the choice of one.........the grinder with thin disc would be it.

[jsp]

Thanks both for your input.

I have stitch welded with my MIG welder 170A.

[lexi]

Yeah, getting there. You don't waste any time!
Phosphoric acid or Citric acid is good for treating rust on panels.

[jsp]

Could I weld like this so that this corner is gone.

[jsp]

Almost finished hate it to do this but, worth the job saving such an old car:

[RichardW]

Looking good! Wanna come to mind and weld some patches on the similar looking holes in my Visa.... ?

[jsp]

Visa rust here aswell? must be a common issue on PSA hatchback cars.

[RichardW]

Visas rust everywhere

[Gibbo2286]

I recall when the Rootes group brought out their first mono-constructed Hillman Minx, at 18 months old we had cars with the front end of the rear leaf springs together with the shackle brackets coming up through the floor in the rear footwell.

At that time we did all the welding with oxy acetylene and I spent many hours cutting 18 gauge sheet steel and lying on my back welding it in.

There were no ready made panels, everything had to be cut and made to pattern.

I thought all those cars had gone to the scrapyard but I see there's a black one in one of the new tv crime shows.

[jsp]

Its just flew through the mot with one advisory on the wishbone [probably] the bolts in the ball joint.