Rust help...

Right, ive now got a Mk1 and ive decided i want to try and do as much as i can myself, rather than pay a garage to sort it/fit parts. I think ill need a new sill, maybe need to repair 2 doors and one wing. Any advice/things to look out for/best way to do it?

Is it a fairly simple thing to do? Ive read some only instructions, and cant imagine it will be that difficult for a 27 year old with half a brain?  

I have a '82 1.6 GTi, in black.

Thanks in advance,

Scott

Try and get a night school course at the local college.  Be it a car restoration course or just mild steel mig welding course.

May cost about £200 but it will pay for itself. learning to weld from a professional makes it much easier and you end up using a lot less filler.

Failing that look on mig-welding.co.uk and on the retro rides forum as there is a very good guide on making panels and welding/finishing the repair.

Other than that get the best welder you can, ideally as close to 200 amp as you can as the higher amp welders are more stable at low power.

The mig forums will help you decide on gas etc and on makes of welder.

Hope that helps,
Jon.

go buy a mig welder (not a really cheap one)….

get some scrap metal and learn how to weld
it wont take long to get ok at and as long as you know how to Weald a grinder it dont matter how the welds look

unless you want it perfect…. in which case, hand it to someone else lol.

as regards to the best way to do things, if its something thats bolt on like a wing, buy a new one. same as the doors if there cheep enough.
but for sills, there not easy to find
but only cut out what is rust, no need to cut good metal as it can make weak points.

iv done all mine myself and on my project page it shows some bits and bobs.

click on the link below to have a quick look

http://www.vwgolfmk1.o…wtopic&t=77754&highlight=

im doing EVERYTHING myself and when i started it was daunting but now im stuck in its REALLY easy


hope some of this helps
oh and welcome to the site

Would you recommend trying to repair rust to keep original panels, or would you buy non-genuine? How much of a difference is there? My Mk2's barely needed much cosmetic work, but can see the Mk1 needing alot of rust-work.

Id ideally like to keep all original panels and sand down to bare metal, repair rust myself, then prep and spray it myself with a mate.

I think the rusted panels can be saved, and they line up so much better than the one "non-genuine" wing

It depends.  if you get good at making panels then the world is your oyster, as so to speak.

The usual thing is to make repair sections where possible to keep the cost down, but for the more difficult section, such as the rear valance or rear arches, you're better buying replacements.

I would always try to repair front wings as pattern parts are poop and vw ones can be dear.

Try and get the welding neat so you don't need much filler as the less filler you use the better.  

Make sure you remove or treat every last inch of the corrosion behind a panel too, i.e when you replace a sill, treat the inner sill for corrosion and spray with a good weld-through rust inhibiting primer. that way it wont catch fire when you zip the sill up. you can then fire a load of waxoyl, (or similar,) into the cavity.

Rust is def like cancer, if you don't get it all and take enough preventative steps it'll be back, often before you've even finished the car lol

Jon.

Cheers for your help guys. Stripping the car begins soon...now i can ponder over wheels and colour....mmmm