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easiest way to repair plenum

Started by _Kush_ , Jul 21 2010 06:00 PM

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56 replies to this topic

#1 _Kush_

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Posted 21 July 2010 - 06:00 PM

Hi chaps, so I'm pulling the hatch apart and after I removed the dash and then the sound deadener mat I noticed that the plenum is rusted to buggery. The previous owner also did a crappy half-arse attempt at fibreglass repair on it also. I initially thought that I'd weld in new plates where the rust was, but after closer examination I was shocked to be able to see straight through to the firewall in a few spots. Does anyone know how I can attack this? Or even get access to the front of the plenum?

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#2 _dirtbag_

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Posted 21 July 2010 - 06:09 PM

Hi Kush. I think the easiest way for you to get over this hurdle is to just send your car to me so I can have it.

See, I'm helpful : )

Do you want my address?

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#3 _Kush_

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Posted 21 July 2010 - 06:22 PM

That's not the kind of help I was after, Tim. As I've told you before, you can BORROW it for a few months (maybe spruce it up a bit) then send it back all shiny and new

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#4 TerrA LX

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Posted 21 July 2010 - 06:23 PM

Dirtbag that's kind of you to repair his car for him.

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#5 _stu.slr_

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Posted 21 July 2010 - 08:09 PM

post some pics, nothing is impossible to a fabricator/sheetmetallist. type person.

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#6 _Kush_

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Posted 21 July 2010 - 08:31 PM

Yeah I've taken pics and I will post them, but I'm on my iPhone at the moment because I've exceeded my Internet limit for the month :(
it has crossed my mind though, to make up a plastic one so it won't ever rust again..... If I can get the bloody rusty thing out!

Edited by Kush, 21 July 2010 - 08:40 PM.

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#7 mr5000

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Posted 21 July 2010 - 08:43 PM

http://www.gmh-toran...pic=35788&st=50

theres a link to my thread i ripped mine out and fixed it all up best thing you can do is go out and buy a spot weld cutter/holesaw from rytool there about 20 bux

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#8 _Kush_

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Posted 21 July 2010 - 09:05 PM

http://www.gmh-torana.com.au/forums/index.php?showtopic=35788&st=50

theres a link to my thread i ripped mine out and fixed it all up best thing you can do is go out and buy a spot weld cutter/holesaw from rytool there about 20 bux

thanks mr5000, Thats helpful. It's a bit of work. Bugger! Oh well, it's gotta be done.

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#9 mr5000

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Posted 21 July 2010 - 09:08 PM

hot tip dont do it in your thongs day before new years already half cut standing on the motor it hurts when ya fall
:fool:

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#10 _Kush_

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Posted 21 July 2010 - 09:34 PM

Hahahahaha! LMAO!

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#11 _dirtbag_

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Posted 21 July 2010 - 10:35 PM

I really think you should just send it to me, then you don't have to worry about it. EVER!!! bwahahahha : )

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#12 _Kush_

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Posted 22 July 2010 - 09:36 AM

I really think you should just send it to me, then you don't have to worry about it. EVER!!! bwahahahha : )

Dirtbag, you are a scoundrel of the highest order!

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#13 _stu.slr_

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Posted 22 July 2010 - 11:36 PM

I really think you should just send it to me, then you don't have to worry about it. EVER!!! bwahahahha : )

"cos your jus a teenage Dirtbaag baabee!"

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#14 _Kush_

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Posted 23 July 2010 - 09:07 PM

Today I got one of those spot weld cutters and started to use it. After I cut 10 spot welds, it was blunt. So I flipped it over and got another 10 spots done. Then I used an 8mm drill bit for another 6 spots and it went blunt. WTF? Was I supposed to use cutting compound on the spot weld cutter? It's only sheetmetal. Not like it's some sort of titanium alloy....... I've still got approximately 200000 spots to go!

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#15 _dirtbag_

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Posted 23 July 2010 - 09:22 PM

I use cutting compound with my spot weld drills but they still go blunt pretty quick. I use the 2 blade slot drill style drills, not the tiny hole saw style.
i now just use the die grinder to get through spot welds. It's heaps quicker. I hate un spot welding panels. Keep going though, I know you'll get it done.

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#16 mr5000

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Posted 24 July 2010 - 08:14 AM

the blades on mine didnt go blut it was the guide rod that went blunt and then it starts wandering also if your not already doign it centre punch the spot welds before

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#17 _Kush_

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Posted 24 July 2010 - 03:44 PM

the blades on mine didnt go blut it was the guide rod that went blunt and then it starts wandering also if your not already doign it centre punch the spot welds before

yeah, I centre punched them. I found it didn't wander if I had the drill spinning, then pushed it down onto the job. When I did the first few, I put the cutter onto the panel before I started the drill and it went all over the place. I'll have a go at the die grinder trick now, I think. See which method works best for me

thanks guys

Edited by Kush, 24 July 2010 - 03:47 PM.

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#18 76lxhatch

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Posted 24 July 2010 - 09:27 PM

Using a slightly bigger bit (spot weld bit) than the spot, e.g. 8mm bit on 6mm spot welds, makes them a lot quicker to drill out and the bit lasts a lot longer because you don't hit the weld as often. Down side is bigger holes of course

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#19 rodomo

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Posted 24 July 2010 - 10:36 PM

I use a 1/8th pilot hole then a 3/8th with and obtuserer (is that a word? :blink2:

) angle ground into it.

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#20 Pop's-SS

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Posted 31 July 2010 - 04:02 PM

Graham (LX5008) had to do the plenum chamber on his Hatch so if you contact him and or click on the link under his posts then it might be of help.

You will have to go just over 1/2 down the photo list to see the pics.

Regards ... Barry

Edited by Pop's-SS, 31 July 2010 - 04:03 PM.

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#21 LX2DR

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Posted 09 August 2010 - 09:34 PM

This link takes you directly to Grahams repair.

LX5008 Plenum rebuild

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#22 mr5000

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Posted 11 August 2010 - 08:13 AM

once the spot weld cutters start to wander its coz the pin in the middle starts to mushroom over repointy it and youll be sweet

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#23 _Kush_

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Posted 11 August 2010 - 09:40 AM

I got the cover off and gave the inside a going over with a wire cup brush on the grinder. It's bloody scary in there. God knows how much fibreglass the previous owner used over the rust holes. I'll post up some pics when I can.

p.s. How important is the plenum chamber anyway? It takes up a lot of space under the dash. Would it hurt to make it shallower?

Edited by Kush, 11 August 2010 - 09:42 AM.