Car boot rust repair

[Kram]

This is one of my tree customers cars, we were talking about my car and its recent repair that I'm yet to paint, and she showed me this which she did herself many years ago with aerosols and a big tub of filler. She found it difficult to sand, and so skipped that part. I dont think primer was used.

I'm imagining it originally rusted from inside due to window leak inside the panel or blocked drain.

Can I fix it, to a good standard? My initial thoughts are to swap the boot unit but there do not appear any listed for a 2000 year estate.

Or to sand it back removing all filler and any loose rust, which I'm sure will be lots, until sound metal, somewhere underneath, treat it with rust coverter.

If it would require welding or messing with the glass, that would be beyond me.

What do we think? I may suggest sanding a small area to see how deep the rust goes, but I think theres a good chance its held together by filler and needs a new panel.

 

[Misterg]

You'll be needing one of these:

Pardon our interruption...

I doubt that there'll be any "sound metal underneath", and suspect that the glass would need to come out. New tailgate from a breaker for me, 100%.

 

[steveo3002]

id only get involved swapping it for a used one , im sure one will come along sooner or later

patching it up...well thats how you get a bad name for yourself , customer only wants a lash up but will gladly tell everyone you did it when it looks naff

 

[badabec]

"I'm fully booked for six months".

 

[daedalusminos]

Looks like the rust has spread from the glass flange spot weld. Get a better replacement....IMO better to work on something that hasn't been bodged

 

[marlinspike]

It would be a lot of work imo. Glass needs to come out to do a good job. The cost would seem uneconomic for a car that age. Waiting for a good used hatch panel makes more sense, though there aren't any on ebay atm as I've just had a look.

 

[harveyp6]

Nirro Ltd - VW, Audi, Skoda and Seat Quality Used Parts in London

www.nirro.co.uk

Have you tried the above?

 

[steveo3002]

"I'm fully booked for six months".

six years

 

[Gareth J]

Is it worth the faff doing anything? The car is 26 years old...

 

[Smallfry]

Not worth the bother. Should be able to get a better one from from eBay or breakers. Mind you, Audi and BMW are not good in the rusty panel department, so maybe not.

 

[MattF]

Is it worth the faff doing anything? The car is 26 years old...

I'm banking she's fit, & he's trying to get in her good graces.

 

[Misterg]

there aren't any on ebay atm as I've just had a look

I suspect that it's not worth people's trouble listing parts for old, non-classics on ebay - I think it's a ring around the local breakers job, or lodge a request with one of the salvage agencies (Parts Gateway or similar).

 

[Nomad]

I've just repaired something similar (rusty hole much smaller that yours running down the bootlid from the rear screen rubber).
It's an older car, parts are unobtainable, grind out the rust to see the size of the problem, zinc primer, weld a plate behind the hole to support the top coat of filler, sand smooth, paint using rattle cans.
Results look 100% good from a couple of feet away so I'm calling that a pass.
If it was a cherished classic that would live for another 20 years it makes sense spending time & effort, for a well used daily transport - a quick fix that will last a couple of years could well outlast the car.

Horses for courses...

 

[Kram]

I'm banking she's fit, & he's trying to get in her good graces.

Unfortunately not she is near double my age, and I am not young.
However she is a pleasant, easy customer to work for, who happily paid me extra for the tree last week. It did take a few extra hours due to tip site being closed and having to go back the next day, but that was our of our control.

Tree work is currently a bit light and to be honest I am not that picky with the work I am willing to do provided I can do a good job of it, and it would be helpful practise before I do my own car.

Now say can find a rear boot/tail panel. Its obviously quite large. I guess it could be wrapped up in a few tonne bags and strapped to a roof rack, perhaps thats the only way to transport one by car?

 

[harveyp6]

Now say can find a rear boot/tail panel. Its obviously quite large. I guess it could be wrapped up in a few tonne bags and strapped to a roof rack, perhaps thats the only way totransport it by car?

Is the car road legal? If so, drive down in the car, swap the tailgates over, then either leave the other one there or cut it so it will fit inside the car and dispose of it when you're back and have used everything you need from it.

I did that many times back in the day.

 

[Kram]

I've just repaired something similar (rusty hole much smaller that yours running down the bootlid from the rear screen rubber).
It's an older car, parts are unobtainable, grind out the rust to see the size of the problem, zinc primer, weld a plate behind the hole to support the top coat of filler, sand smooth, paint using rattle cans.
Results look 100% good from a couple of feet away so I'm calling that a pass.
If it was a cherished classic that would live for another 20 years it makes sense spending time & effort, for a well used daily transport - a quick fix that will last a couple of years could well outlast the car.

Horses for courses...

Please do you have a photo of your repair and the process if you have any?

 

[Nomad]

@Kram Mid-repair after a backing plate (behind the panel - not flush) had been welded in place and ground back.

Top tip: if you decide to do as I did and weld a support behind, make sure you disconnect the battery to avoid frying the ECUs (do you have codes to unlock the radio if needed?). Ask around for advice - I was told welding with the battery connected was risky... do you feel lucky?



Just add a skim of filler, sand then rattle can .. no point aiming for perfection on a car parked on the street that regularly gets carpark dents.

It’s a huge improvement over the crusty “rust and fresh air” section that was there originally.

Polishing out the rust streak below was also a good result.

A good sized scabby crease above the filler cap was also given a coat of filler + tlc, repair is invisible from a couple of feet away unless you are looking for it.