Rust? anybody rust? Anybody for some rust? - BMW M5 Forum and M6 Forums

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Old 21st April 2012, 21:37   #1
Mr.Devere
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Rust? anybody rust? Anybody for some rust?

Chaps, for info really, input would be appreciated........

Firstly a couple of pics of the car from the top side for those that have not seen it before.............

Oct 1999, 114k, drives great, engines strong, a modern classic in every way...........







As can be seen this is not a car that is ready to be given up on just because of rust, I will endeavour to correct this.......

Took the rear wheels off today for cleaning, long overdue, not had the car up on stands since last year. I noticed a bit of rust around the jack pad, mainly the paint hole where the rust had removed the paint. This is on the UK drivers side rear.



I had checked these last year after Cemessi's thread and eventual strip out of his M5, had noticed bubbling but nothing that had blown through. There has been quite a progression over the last 6 months. I removed the jack pad and began to pick at the paint.



There was quite a build up so just kept going until I reached a point at where the rust seemed to have stopped and the paint & metal were intact free from corrosion.



I removed the sill cover and found the rest of the sill looked ok (that is until it reaches the front jack pad)...........quite happy about the fact it is contained to this rear section around the jack pad and the sill is in good condition.



I picked out most of the heavy stuff I knew it wasn't good that I was removing bits of rusted metal about 0.5mm thick.......



Then got the dremel out and started to remove the grained in rust.....





Towards the rear end of the sill the metal was shot, nothing left, poked about a bit and created this mess......



In these next pictures if you look through the holes you can see the insides of the panels, looks like the rust has not crept too far away from the jack pad area.







Last year I had the standard rust removed from the petrol cap area, rear panel above the bumper and quarter panel again just above the side of the bumper, after which I coated the inside of both the rear arches with a heavy axle grease to keep the moisture away, been like this for about a year, looks OK....



Time ran out so had to stop, I am thinking of cutting out this entire lower sill section.......



I can measure up and see how the jack pad area anchors to the car. I could then fabricate a new piece and weld in it. Agreed a lot of work but can't see any other options, can't leave it, the car more than deserves the effort....

FYI, The opposite side seems fine, I poked at the paint and it solid, no sign of flaking or bubbling, however the same can not be said for the front, looks a mess there as well, next on the list..............



any input is greatly appreciated................

Thanks

Mike
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Old 21st April 2012, 22:21   #2
feeblebob
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It sucks that our climate seems to eat away at these cars I must admit this isn't something that I've accounted for when I get mine sorted and I don't really have a clue about bodywork and corrosion, I'm not a body shop expert. I remember the dilemma that Scott faced and it's a hard one. I'd get it sorted mate if I were you, your car is great in every other truly worth it
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Old 21st April 2012, 22:23   #3
SodeM5
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Jesus fc..I have been thinking of remonving my under tray plastic to see whatīs in there..after seeing these photos donīt really want to do it anymore if I also find this in my car...that is some serious corrosion. On the other hand, your climate is even more wet than ours. Hopefully I Donīt find this..
luckily that is still replaceable
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Old 21st April 2012, 22:49   #4
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Jesus fc..I have been thinking of remonving my under tray plastic to see whatīs in there..after seeing these photos donīt really want to do it anymore if I also find this in my car...that is some serious corrosion. On the other hand, your climate is even more wet than ours. Hopefully I Donīt find this..
luckily that is still replaceable
If we find rust holes,we weld it next week.
No worries


Mike,if you can weld the rocker panel yourself it is not such a nasty fix.

Get a rocker panel and generous replace the area.

Sealing it sufficient with rust primer and wax from the inside should make the repair last.
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Old 21st April 2012, 23:01   #5
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To be honest not that depressed about it, I think its a 'weak' point on our cars and after all metal rusts, it's what it does. It does look like its only the lower panel of the sill that has corroded badly, the side of the inner arch coming down looks OK, once I have cut away at the metal that is not repairable I will take more photo's and post. I can then decide how to correct it. I will continually update update this thread for reference.
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Old 21st April 2012, 23:01   #6
feeblebob
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Loving your attitude. Why don't you live the next town over from me?
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Old 21st April 2012, 23:04   #7
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Loving your attitude. Why don't you live the next town over from me?
Ha yeah, half the costs of hiring the welder............
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Old 21st April 2012, 23:05   #8
feeblebob
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Absolutely
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Old 21st April 2012, 23:07   #9
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Very bizarre, I would have thought I live in the worst place for rust. My car has been driven every winter with salt all over the place. I had slight bit of rust in that area but it was just a wire wheel to fix and some locktite rust remover and that was it. Must be the salt air and warm eating your English cars.
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Old 21st April 2012, 23:15   #10
feeblebob
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No, it's the crazy car tax, price of petrol, potholes......
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