Devious 4x4
14th October 2012, 07:39 AM
Gday, Just thought Id show my latest project on the Patrol.
When I bought it a few years ago there was rust in the roof above the gutter on the drivers side above the rear window.
I ground the paint back and found it was just surface rust with no holes through the metal. So I rust treated it and primed it and that was it, I never painted it, which was a bad move as the rust came back and much worse!
So I ground it back again and found there were a heap of holes in the metal.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/548718_10151129262401871_1510090859_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-snc6/183456_10151129262196871_107405516_n.jpg
So I figured I might as well cut the rust out and fix it properly. So I cut out the rusty areas and found the inner frame of the roof also had surface rust and lots of moisture in there, and the small hole I cut also had a heap of rusty metal flakes behind it.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/525855_10151129262271871_533165807_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/65454_10151129262311871_2055500512_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/535928_10151129262496871_1979361833_n.jpg
So I cleaned the inner frame up with a wire wheel on the die grinder, rust treated the areas and coated them in a Kill Rust epoxy paint to prevent more rust from forming.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/32355_10151129262001871_1599078486_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-snc6/223372_10151129262741871_242455122_n.jpg
I then cut out replacement sections from some steel I had, which I had zinc coated on the inside to prevent future rust and welded them in. I also removed the rear side windows, so I could lower the headlining to the back seat, which would allow me to keep an eye on any potential fire risks. I also had an extinguisher handy just incase!
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-snc6/254540_10151129262636871_1746857705_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/397296_10151129261916871_446524662_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/543263_10151129262821871_1528905184_n.jpg
After I cleaned up the metal it only needed a little filler to smoothen everything up and it got a coat of 2K high fill primer.
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/426338_10151129262886871_143360808_n.jpg
I have to let the primer cure for 24 hours, So it will get a coat of paint during the week. The job took me about 7 hours in total, and that was just taking my time. A decent mig welder would make it quicker, but ive only got a gasless mig, so there was lots of cleaning up welds involved!
Thanks for looking!
When I bought it a few years ago there was rust in the roof above the gutter on the drivers side above the rear window.
I ground the paint back and found it was just surface rust with no holes through the metal. So I rust treated it and primed it and that was it, I never painted it, which was a bad move as the rust came back and much worse!
So I ground it back again and found there were a heap of holes in the metal.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/548718_10151129262401871_1510090859_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-snc6/183456_10151129262196871_107405516_n.jpg
So I figured I might as well cut the rust out and fix it properly. So I cut out the rusty areas and found the inner frame of the roof also had surface rust and lots of moisture in there, and the small hole I cut also had a heap of rusty metal flakes behind it.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/525855_10151129262271871_533165807_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/65454_10151129262311871_2055500512_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/535928_10151129262496871_1979361833_n.jpg
So I cleaned the inner frame up with a wire wheel on the die grinder, rust treated the areas and coated them in a Kill Rust epoxy paint to prevent more rust from forming.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/32355_10151129262001871_1599078486_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-snc6/223372_10151129262741871_242455122_n.jpg
I then cut out replacement sections from some steel I had, which I had zinc coated on the inside to prevent future rust and welded them in. I also removed the rear side windows, so I could lower the headlining to the back seat, which would allow me to keep an eye on any potential fire risks. I also had an extinguisher handy just incase!
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-snc6/254540_10151129262636871_1746857705_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/397296_10151129261916871_446524662_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/543263_10151129262821871_1528905184_n.jpg
After I cleaned up the metal it only needed a little filler to smoothen everything up and it got a coat of 2K high fill primer.
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/426338_10151129262886871_143360808_n.jpg
I have to let the primer cure for 24 hours, So it will get a coat of paint during the week. The job took me about 7 hours in total, and that was just taking my time. A decent mig welder would make it quicker, but ive only got a gasless mig, so there was lots of cleaning up welds involved!
Thanks for looking!