"Reuben" wrote in message
m...
I have a 1983 VW Passat GL5 which is in reasonable condition barring
some serious rust on the training edges of the doors and the tailgate.
Professional repairers seem reluctant to take on repairs like this -
they want to replace the doors (possible) and the tailgate (not
possible to buy new tailgate now).
I'm considering doing the repairs myself and I'd like to hear from
anyone who has experience of this kind of job in relation to materials
and methods.
I'm realistic about what I can expect to achieve - I just want a
passable job to keep the car legal. If it turns out really well,
that's a bonus.

Thanks.

==================
These are cosmetic repairs and the simplest and cheapest method is to cut
away the rusted sections and replace with new metal pop rivetted into place.
Basically use a pair of tin snips to cut away the damaged material and then
cut a cardboard pattern to cut replacements from new metal. Most car spares
shops sell sheets of suitable repair metal - Zintec is the best if you can
get it. Make sure that there is sufficient overlap on the replacement metal
(at least 1") and feed it *under* the original metal. Clamp the new to the
old as well as you can and drill 1/8" holes through both layers for your pop
rivets (stick to 1/8" rivets). If you need to put a lip on - e.g. for a
door edge prepare a bend in the new metal before starting the clamping /
rivetting. Finish off the new door edge by hammering or crimping with
pliers or mole wrench.

When you're sure that your new patch is securely rivetted clean the whole
area and do a cosmetic finish with body filler and spray with aerosols to
finish off. If possible try to hammer in the heads of the pop rivets so
that the body filler covers them.

If the rusted areas are quite small you can use thin mesh instead of metal.
You can buy this with 'Isopon' etc or separately. Clean the area to be
repaired - remove all paint and rust. Then use a little body filler (Isopon
or similar) to hold the mesh in place. Allow to set and then use more filler
to complete the job.

Don't be tempted to use either of these methods on anything structural -
they're for cosmetic use only.

Cic.