RogerH Posted November 11, 2018 Report Share Posted November 11, 2018 Hi Folks, the boot lid on the white 4A is showing signs of the dreaded rusticulation. Last year I was given a lid that had a few signs of damage. The handle hole was buckled as if the handle was wrenched upwards.. Otherwise it looked reasonable for repair. Last week I measured and measured again before cutting the rusty bottom off. The problem with measuring is measuring the right bits. !!! I temporarily fitted the repair panel that I had knocked up the week before. and this looked good when sat in position. The corners were a little sticky outy. This was sorted by pulling them into place and putting a dob of weld to hold the shape. When I then put the lid in place on the car I found the lid no longer fitted. With the repair panel positioned to give a nice shape to the profile I found the bottom of the lid to be a good 20mm too far forward. Thus it would not clear the rubber seal on the bottom lip of the boot cut-out. Using CAD technology (Cardboard Aided Design) I found that the vertical portion (where the number plate goes) of the lid was in fact pushed forward as if it had been shunted from behind. The actual skin looks pretty good so I suspect it is the thicker side ribs that are holding the shape wrong. Tomorrow I shall start to make some new side ribs When I removed the paint before the repair I noticed there was quite a lot of filler around the handle area. Now I know why !!! And on top of that my expensive bird feeding station (metal pole with dangly bits) fell over under the weight of the peanuts etc. It is powder coated mild steel. It is 2 years old and rotten under the paint. next spring I shall refurb it as it should have been before I bought it. Roger Quote Link to post Share on other sites
John Morrison Posted November 11, 2018 Report Share Posted November 11, 2018 Well you wouldn't want to have nothing to do Roger - would you? John. Quote Link to post Share on other sites
rcreweread Posted November 11, 2018 Report Share Posted November 11, 2018 Roger Have you not got a metal shrinker/expander - if you have the latter, use it on curved edge to expand it, and the bottom of the boot should move backwards, shouldn't it, or have I misunderstood your issue?! cheers Rich Quote Link to post Share on other sites
Geko Posted November 11, 2018 Report Share Posted November 11, 2018 1 hour ago, RogerH said: Using CAD technology (Cardboard Aided Design) haha, very good Quote Link to post Share on other sites
RogerH Posted November 11, 2018 Author Report Share Posted November 11, 2018 8 minutes ago, rcreweread said: Roger Have you not got a metal shrinker/expander - if you have the latter, use it on curved edge to expand it, and the bottom of the boot should move backwards, shouldn't it, or have I misunderstood your issue?! cheers Rich Hi Rich, You are correct. However it will give me a good reason to remove the stiffeners/reinforcing as there is rust underneath. Easy enough to make new stiffeners/reinforcing Hi John, i do have other things to do - eg. bird feeder stations. Roger Roger Quote Link to post Share on other sites
Grahamgl Posted November 11, 2018 Report Share Posted November 11, 2018 1 hour ago, RogerH said: Hi Rich, You are correct. However it will give me a good reason to remove the stiffeners/reinforcing as there is rust underneath. Easy enough to make new stiffeners/reinforcing Hi John, i do have other things to do - eg. bird feeder stations. Roger Roger Roger, I have sent you a PM. Graham Quote Link to post Share on other sites
RogerH Posted November 11, 2018 Author Report Share Posted November 11, 2018 Hi Graham, in the last couple of days you have said that you have sent me a PM. Haven't received any. Roger Quote Link to post Share on other sites
stuart Posted November 12, 2018 Report Share Posted November 12, 2018 Your bird feeder collapse just illustrates neatly the problem of rot getting under powder coating. Stuart. Quote Link to post Share on other sites
RogerH Posted November 12, 2018 Author Report Share Posted November 12, 2018 Hi Stuart, I think it exactly explains the problem with powder coating. The corrosion gets under neath the coating and can't be seen until it is to late. The manufacturers of these goods wouldn't use it if it was more expensive than paint of galvanising. Roger Quote Link to post Share on other sites
RogerH Posted November 12, 2018 Author Report Share Posted November 12, 2018 Hi Folks, just removed one of the flange stiffeners of the dodgy boot lid and compared it to a know good lid. See the pic below. The gap at the arrow is +15mm which compares nice;y when the lid is in situ and the lower boot seal sticks out. Roger Quote Link to post Share on other sites
BlueTR3A-5EKT Posted November 12, 2018 Report Share Posted November 12, 2018 18 hours ago, RogerH said: Hi Rich, You are correct. However it will give me a good reason to remove the stiffeners/reinforcing as there is rust underneath. Easy enough to make new stiffeners/reinforcing Hi John, i do have other things to do - eg. bird feeder stations. Roger Roger Replace the grotty bit with a bit of exhaust pipe? https://www.ebay.co.uk/itm/Any-Size-Repair-Section-Stainless-Steel-Exhaust-Pipe-Tube-Expanded-Swaged-Fit-/352192809933 Peter W Quote Link to post Share on other sites
RogerH Posted November 12, 2018 Author Report Share Posted November 12, 2018 Hi Pete, that took a bit of thinking about. I was wondering where to fit the pipe on my boot lid. Good idea. Roger Quote Link to post Share on other sites
RogerH Posted November 12, 2018 Author Report Share Posted November 12, 2018 Hi Folks, good news. I have removed the side flange stiffeners and the skin has sprung back to its correct shape (ish). I've ordered a small sheet of 1.5mm zintec plates mild steel. Should be fun sticking it all back together. Roger Quote Link to post Share on other sites
stuart Posted November 12, 2018 Report Share Posted November 12, 2018 4 minutes ago, RogerH said: Hi Folks, good news. I have removed the side flange stiffeners and the skin has sprung back to its correct shape (ish). I've ordered a small sheet of 1.5mm zintec plates mild steel. Should be fun sticking it all back together. Roger Treat yourself to a spot welder Roger. Stuart. Quote Link to post Share on other sites
RogerH Posted November 12, 2018 Author Report Share Posted November 12, 2018 Hi Stuart, I bought a spot welder three years ago when I was doing the nearside sill. Had to rewire the whole house to get the amps into the workshop. (changed a CB to a c grade) The side flanges of the lid now have so many holes that a spotwelder would have trouble finding somewhere to sit. I can use it on the repair panel. Roger Quote Link to post Share on other sites
TorontoTim Posted November 14, 2018 Report Share Posted November 14, 2018 On 11/11/2018 at 12:49 PM, RogerH said: Easy enough to make new stiffeners/reinforcing I hear that there's a pill for that these days... Quote Link to post Share on other sites
RogerH Posted November 14, 2018 Author Report Share Posted November 14, 2018 Quote Link to post Share on other sites
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