BMW E30 Rear Arch Repair Welding | How To Repair A Rusty Wheel Arch | 017

right so i haven't spent quite a long time laying on my back on here dealing with rust i'm finally now getting to the part that i've been putting off and procrastinating about which is the rear arches i had quite good success with the rear battery box which you may have seen in a previous video so i'm feeling fairly confident i can do it but there was no way i was going to be able to make the make the shape myself out of sheet metal so i've gone ahead and bought myself some rear replacement arches which i'll be able to cut parts out of and use uh they're just on ebay i'll put a link to those in the description uh so the first things first i need to get things out the way so i'm going to remove the rear bumper and probably this side strip and then i can see what i'm really dealing with and after that i guess it's a case of getting the angle grinder out cutting the rot out making patches with this welding it all up let's see how it goes [Music] right starting with the rear bumper i believe it's just these two torx torx screws up there let's see if this comes off it should just slide off once i unscrew those typically it was a t55 i had a 50 and a 60 but the 50 with the old foil trick seems to have worked to treat there we go these are a 10 and they look pretty rusty unfortunately let's hope they come out so there's always one [Music] and with those removed it's time to crack on the passenger side arch actually doesn't look too bad there's a little bit a little bit of rust going on at the the bottom corners of both sides but the main problem on this side really is the the inner arch there's a few rust holes in there so i'm going to need to sort that out i have a replacement panel for the inner arch too i think i'm going to start on this side which is the driver's side because the most obvious rust is here which really needs attention and of course the inner arch on my area is bad too the rest of this one not too bad though so fits up reasonably well i think [Music] so [Music] as you can see i'm marked on in marker pen where the limits are of the patch panel i've bought just so i can make sure i don't do anything really stupid and chop more out than i have to replace as you can see there's quite a bit of rust still there to cut out from the inner arch which i need to remove and replace that too i've also got to cut quite a bit more of this uh side skirt area because i'm revealing some rust in that gap there which uh looks pretty bad to be honest but i already knew this was rusty as you can see the jacking point it's pretty pretty bad too so let's see how far that goes but of course my patch goes up to here so i'm not going to go too much further but the top i think we've uh we've hit solid metal there so i think that's a reasonable point to stop at right let's cut some more of this inner arch out and see what more we find [Music] me [Music] right with more of that inner skin cut away i think i'm finding a bit of a problem here peering into the hole i've cut here i can see there's actually quite bad rot within the bottom of this silt and it goes all the way up to just beyond the jacking point really to be honest the checking point is pretty sketchy so what what i've done to be able to address this and cut it out i've had to move the axle stand a bit further up just to give me a bit more room to work over here i was put an extra one in and firmed it up just for support and bear in mind there's no rear beam on rear wheels or diff or anything like that so the back end's as light as it can be so i don't expect this to cave in i think it's i think it's pretty solid to be honest and now of course i've got room to cut this out and work in there [Music] so [Music] so [Music] [Music] foreign [Music] [Music] right so that's all the rock cut out and all the edges cleaned up so now i need to think about where to start really there's multiple skins here one two three and this obviously is a separate separate piece um i haven't got a repair kit for this of any description so i'm just going to try and make stuff up out of sheet metal i have i think i'm going to start with the inner skin then do the the box middle skin and then worry about the outer area this is the shape i need to cut what i'm going to do is i'm going to cut a generous piece of the sheet metal and then i'll start working about there working on the specific shape but playing with this long large piece is a pain in the ass so i'll cut myself a smaller one so so [Music] so i've got my patch welded in here ended up cutting it into three parts because i was having a hard time with the with the shaping of it as one um it was actually quite a fiddle but got there in the end i ground down the welds a bit it's nice and smooth here which is going to be visible well when the wheels off and here i've just took the tops off i'm going to leave it as it is because it's quite well hidden so the next thing to do is to cut along this line to match up with this seam with the sill seam there and um then it should all be the the right height and then i can move on to the inner skin here for this uh chassis rail style thing within within the sill but so far so good [Music] so i've sprayed a bit of welt welter primer over it just to stop it from flash rusting now i'm moving on to this inner skin so this is a like a pressed piece of steel and as you can see it's it's got like a corrugated shape to it i'm never going to be able to bend a patch to to meet up with that perfectly not in a month or sunday so i'm not even gonna try so what i've done is i'm doing a bit of cardboard aided design and i'm gonna slip this in behind there so i can weld it to it at certain points and then figure out how i'm going to extend these off or fill these gaps afterwards but that should be that should be very sturdy if i can get metal welded in like that this is this here is actually the support the inner support for the jack the rear jacking point so i definitely want to make sure this is uh solid as a rock [Music] so [Music] [Music] [Music] uh [Music] [Music] so [Music] so [Music] so [Music] [Music] [Music] all right again [Music] not quite done so so [Music] right so i've welded in the jacking support so it's pretty much a semi-circle of metal i've extended that down and i've left it a bit long so i can cut it down before i put the outer skin on that way it can contact and give the jacking point the support it's supposed to have from factory very solid i'm quite happy with it so the next thing to do is to get a bit of primer on this just to make sure it doesn't rust from the inside out and then i'm going to turn my attention to the arch uh i'll once i've got the arch on i'll be left with a window here and then i'll worry about patching that window in afterwards but let's move on to the arch now so although i've got a full rear arch repair panel i'm actually only looking at doing the front at the moment the rest seems quite solid so the first things first i'm going to cut this repair panel down so that i'm not dealing with this unwieldy panel and that way i can just focus on the area i'm working on the method i think i'm going to use and i've seen this i've seen this method on youtube before and other people have used it very successfully is i'm going to match up my repair panel with the existing bodywork on the car and get it held on firmly and then i'm going to cut through both the patch skin and the car skin with an angle grinder something like that and that way i'm going to end up with a patch that's a perfect fit for the hole i'll have then cut in the car's body work i've never done anything like this before so it's a bit worrying but in theory it should work perfectly right let's cut this patch down [Music] just glue it on it'll be right [Music] that looks like that [Music] [Music] so [Music] so [Music] all right now for the moment of truth [Music] need to finish it off a little bit in a couple of areas but i think it's going to work just fine yep think she'll be able to work with that not bad at all right so you saw i've got my patch panel cut and that was actually very successful so i'm really pleased about that the next thing i'm going to do is something i've seen some professional garages do online of course and that's welding a little support panel behind i've just used another bit of the patch that i didn't use which is obviously a perfect fit so i'm going to get this welded in here and what that's going to enable me to do is have an easier time lining this new patch up but also make life much easier when i'm welding this new patch on because it'll prevent me from blowing through as easily because obviously this is very thin sheet metal so i'm going to get that welded in there probably put another one or two on here and then i can move on to fitting this on [Music] and getting it permanently welded back into place [Applause] this [Music] [Music] so right so i've got my support pieces all welded in around the hole now and this sits on them really quite nicely quite pleased with that so the next thing to do now is the scary bit which is welding all the way around this to get it as hopefully as seamless as possible so the way i'm going to go about this i'm going to really take my time i'm just going to do tack welds here and there until i've welded the whole thing and there's no more gaps from reading and from what advice other people have given me i really need to take my time with this because if i put too much heat into the panel it could warp and then i'll end up in a really frustrating situation where i've gone to a lot of effort it looks like crap i've got to be patient right let's get the welder revved up [Music] so [Music] [Music] so [Music] so [Music] it's that's the first round of welding done and it's it's in really solidly reasonably pleased with how that's gone took bloody ages because i was i was being very cautious giving it plenty of time to cool down so the next thing to do is to flat disc all the welds which will reveal any gaps that i may have missed and then i can do a second pass of welding so far so good [Music] [Music] [Applause] [Applause] right so that's the rear rear arch outer skin welded in and it's absolutely bloody solid i'm quite pleased with how that's gone to be honest although it's taken many hours more than i anticipated i mean it's not perfect but once there's a skimmer filler over it and it's all blended in nicely ready for paint i suspect you won't really be able to tell that that's actually a replacement piece at all which which is exactly what i was aiming for as you saw i just sprayed a bit of a quick coat of primer on it just to prevent it from flash rusting and i think for now i'm gonna leave it like that and come back to do any further tidying up later on but what i really need to do is turn my attention to this jacking point area you'll see me boxing up boxing that up earlier in the video but i think i'm going to stop for today and come back to this in a separate video it goes without saying that i also need to do the inner arch on this side which is currently a gaping hole but i'll probably do that in a separate video after this jack and point repair i'm breaking this into chunks just to make sure people can easily find these videos and they might be helpful if they have the same problem if you've enjoyed watching me struggle with this why not subscribe and watch me struggle with the next parts too but anyway thanks for watching and why not smash the like button if you're that way out cheers [Music] [Music] you

Channel: SPANNER RASH

Views: 133,674

Keywords: spanner rash, bmw e30, e30, e30 project, e30 rear arch repair, e30 build, e30 rear bumper removal, rear arch replacement, rear arch repair, rear arch rust repair, car bodywork repair, car rust repair, welding, welding sheet metal, mig welding, e30 restoration, e30 rust, car restoration, car repair, rust repair, project car, restore it, how to, how to weld, project e30, rebuilding a car, chassis restoration, practical enthusiast, sheet metal, e30 project car, rust hole

Id: mps9WVk6V9g

Length: 27min 31sec (1651 seconds)

Published: Mon Feb 21 2022