Rust

[al & chris]

Just had some welding done on underside of bongo for mot. Looking at other rust areas one of worst is bottom inside lip of tailgate. Does anyone know if anyone does a pre fabricated panel for that area it looks like quite a big job to make one as the tailgate is slightly bowed in shape.

[mikeonb4c]

Hi guys. See this thread:

http://igmaynard.co.uk/bongo/forum/view ... ilit=resin

It was a doddle to do a neat looking glasscloth & resin overlay strip along the bottom of the tailgate, and it cost very little and about 2 hrs work. As well as the external strip, I used a toffee wheel and various scraping implement to remove as much rusty metal along the inside lip of the tailgate, and I then Kurusted it, painted resin on it, then seam sealer.

It seems to be holding up well, though it will be interesting to see if rusting still continues to happe from the inside, and if it attempts to bubble/lift the fibreglass if so. But for the cost and effort, its well worth a go.

[al & chris]

Hi guys. See this thread:

http://igmaynard.co.uk/bongo/forum/view ... ilit=resin

It was a doddle to do a neat looking glasscloth & resin overlay strip along the bottom of the tailgate, and it cost very little and about 2 hrs work. As well as the external strip, I used a toffee wheel and various scraping implement to remove as much rusty metal along the inside lip of the tailgate, and I then Kurusted it, painted resin on it, then seam sealer.

It seems to be holding up well, though it will be interesting to see if rusting still continues to happe from the inside, and if it attempts to bubble/lift the fibreglass if so. But for the cost and effort, its well worth a go.

Had thought about that but ours is pretty bad, separating along inside fold. We also use a bike rack on back, suppose most of weight of rack is along top edge of door so could give it a go. Maybe use Kevlar matting?

[mikeonb4c]

Hi guys. See this thread:

http://igmaynard.co.uk/bongo/forum/view ... ilit=resin

It was a doddle to do a neat looking glasscloth & resin overlay strip along the bottom of the tailgate, and it cost very little and about 2 hrs work. As well as the external strip, I used a toffee wheel and various scraping implement to remove as much rusty metal along the inside lip of the tailgate, and I then Kurusted it, painted resin on it, then seam sealer.

It seems to be holding up well, though it will be interesting to see if rusting still continues to happe from the inside, and if it attempts to bubble/lift the fibreglass if so. But for the cost and effort, its well worth a go.

Had thought about that but ours is pretty bad, separating along inside fold. We also use a bike rack on back, suppose most of weight of rack is along top edge of door so could give it a go. Maybe use Kevlar matting?

Why not. Don't think Kevlar matting is necessary but there are different weights of glassctoth tape, or you could build it up in layers. The overlay strip can be feathered into the original metalwork where the bottom bit of the tailgate moves in. Having got the exterior solid, you can start removing rusty interior and do work on that. By the time you've finished, it'll probably be stronger than original. Need drier / warmer weather for this though unless you have an indoor area and heater. Can it wait until Spring? Post a pic if you can. Doing mine was only about 2hrs work as its such a simple and accessible section.

Also, if you've got rust like that on the tailgate, have you done a thorough inspection underneath etc to see if anywhere else (structural) could be getting into trouble What you save doing a DIY tailgate job you may need for addressing welding work.

[Gasy]

Get a new rear door from a scraper
Probaly be able to get same colour if your lucky