How Much Rust is Too Much

[UNCCHcane]

Obviously recognizing that no amount of rust is too much if you are dedicated, I wanted some feedback on the rust on my 1995 D1. Had it since 1998, love the car, but trying to decide where to draw the line. This isn't the full extent of the rust - the driver side wheel well is toast along with most of the driver floor pan. Passenger side wheel well is toast too. Frame is fine.

I do most mechanical work but I don't weld - I'd feel comfortable cutting out the rusted pans though. I know replacement rear pans aren't terribly expensive but I can't figure out how realistic the salvage job would be. Would welcome any feedback.

 

[mastercamper]

My rear looked like that. I just cut it out and cleaned everything up and put a new floor in it. I have/ had the other places you mentioned maybe not as bad but I'm in the process of sorting it out.

 

[pinkytoe69]

I didn't weld either.

I learned to do so on a D1 that sounds & looks a lot like yours.

$250 at harbor freight, an hour or 2 of internet reading and videos, practice for as long as it takes (not all that long if you aren't timid and understand what a puddle is) you can be on your way to welding that

 

[eburrows]

Learning to weld is pretty easy with a cheap MIG welder from the usual places and some youtube research, but there are a few things to keep in mind with welding above:
1. Burning paint is toxic
2. Unclean steel welds poorly, but flux-core MIG is very forgiving. TIG is very NOT forgiving.
3. Welding on thin sheet is tough. Practice on some sheets that are even thinner first.
4. Unplug your ECU first, to protect it from the high-frequency start arcs and power surges.
You can do it! Just practice a bit first, then you're a welder!
Using a sealant and sheet-metal screws might be more more practical.

 

[pinkytoe69]

1. Burning paint is toxic

Yeah if you can't clean up the area or the back side well, have good ventilation and be ready to hold your breath a lot

2. Unclean steel welds poorly, but flux-core MIG is very forgiving. TIG is very NOT forgiving.

Yep, doesn't have to be pristine with flux core, but if it was too compromised with rust, you're going to have a lot of blow through, which will be hella annoying

3. Welding on thin sheet is tough. Practice on some sheets that are even thinner first.

Yeah home Depot sells 16 and 22 gauge.

16 you can pretty easily string or weave. 22 gauge It's best to do very careful stitch welding tacks

 

[lunchbox]

Define “too much”….

Land Rover Discovery 1 Parts by Froggatts Land Rover & 4x4 Specialists

froggatts.co.uk

 

[UNCCHcane]

Well then - guess I'll get out my grinder and get to work.

 

[UNCCHcane]

Thanks for all the replies btw.

 

[pinkytoe69]

Well then - guess I'll get out my grinder and get to work.

https://www.harborfreight.com/easy-flux-125-amp-welder-57861.html

This is a very solid welder for the price IMHO. Very light & easy to lug around too. Good luck!

 

[Eliot]

Obviously recognizing that no amount of rust is too much if you are dedicated, I wanted some feedback on the rust on my 1995 D1. Had it since 1998, love the car, but trying to decide where to draw the line. This isn't the full extent of the rust - the driver side wheel well is toast along with most of the driver floor pan. Passenger side wheel well is toast too. Frame is fine.

I do most mechanical work but I don't weld - I'd feel comfortable cutting out the rusted pans though. I know replacement rear pans aren't terribly expensive but I can't figure out how realistic the salvage job would be. Would welcome any feedback.

View attachment 65505View attachment 65506View attachment 65507View attachment 65508

I'm guessing you've looked already? But you can find reproduction parts for those areas, that you can weld in.

 

[DiscoClay]

2. Unclean steel welds poorly, but flux-core MIG is very forgiving. TIG is very NOT forgiving.

Funny, TIG is very forgiving, imo: it is much more controllable when working with wonky thicknesses. Whereas MIG (flux core or gas) is more of a Spray & Prey model. The lack of modulation with MIG (on the fly) bugs me.. I end up spending 10x longer doing it "by hand" with TIG.

You can do it! Just practice a bit first, then you're a welder!

100%! I used to teach 12 year olds how to weld.. it's just not difficult and with a little practice you can save a zillion dollars DIY

Using a sealant and sheet-metal screws might be more more practical.

Rivets are not a bad way to go either.