Hi
I've got some rust im a little concerned about in the engine bay... to be honest i havent seen too much of it other than battery trays
has anyone done repairs here as bad as this?
Some how use this piece to fix the above
That is as big as the hole gets.... firewall rust is concerning

Engine bay rust
#1
Posted 06 September 2010 - 05:19 PM
#2
Posted 10 September 2010 - 02:21 PM
#3
_Quagmire_
Posted 10 September 2010 - 04:03 PM
#4
Posted 10 September 2010 - 05:19 PM
#5
Posted 10 September 2010 - 06:42 PM
i dont understand how a engine bay would get so rusty like that... bonnet must be leaking or something
I didnt think it was common
#6
_gtr161s_
Posted 15 September 2010 - 05:14 PM
More than likely it's been residing around a damp or seaside area and out doors most of it's life
#7
Posted 16 September 2010 - 07:56 AM
I repaired some rust on the same model early this year....even had rust behind the passenger bonnet hinge.
More than likely it's been residing around a damp or seaside area and out doors most of it's life
Yeah it came from around Bittern up near phillip island somewhere, amazing it didnt have more rust.. the car is so original, and i recently discovered it has a uncut dash
What about safety with welding in the engine bay? can it be done with the engine in?
#8
Posted 03 June 2025 - 08:46 AM
So 15 years later lol, i've cut out the rust and replaced it best I can... still working on it though.
Sorry not good at welding... and not easy to get good welds with gasless mig.
Also replaced the lower rad support and almost finished the rear tail light.
Attached Files
#9
Posted 03 June 2025 - 08:57 AM
Good work, and good to see you still have the old girl.
#10
Posted 03 June 2025 - 12:09 PM
Do yourself a huge favour and ditch the gasless setup and go for gas.
Over the years quite a few people here have started with gasless, myself included, and everyone ditched it for gas.
The only time I have found gasless any good, is with stuff over 3mm thick, or when I was helping a mate hardface excavator buckets. And that was with 1.5mm wire and a 400 amp machine.
Your welding will be much better and easier with gas.
0.6mm wire, and a bottle from either Bunnings or a Tool shop that you dont pay rent on is the go.
Cheers
Rob
#11
Posted 03 June 2025 - 07:18 PM
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#12
Posted 03 June 2025 - 09:00 PM
#13
Posted 04 June 2025 - 12:53 PM
Gasless is good for working outside in the wind. That is about it……
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Amazing what can be done with strategically placed tarps.
Cheers
Rob
#14
Posted Yesterday, 05:00 PM
Cheers
Nick
#15
Posted Today, 09:04 AM
I've always used Argoshield. I believe the argon helps maintain the arc when welding thin materials on low voltage settings. Argoshield is a mix of argon and CO2.
#16
Posted Today, 12:19 PM
Most places have MIG gas in a mixture that works really well for MIG.
Dont worry about getting into the whys of what is in the mix.
I have 2 gases at home. One for steel MIG, and another for TIG and aluminium MIG.
I have done steel and aluminium MIG work with the same gas over the years.
It still works, but it works a bit better with the right gas.
The type of welding you will be doing, the gas choice wont be super critical, as you wont be needing your welds to be xrayed.
Cheers
Rob
#17
Posted Today, 12:20 PM
yeah my welder doesnt do gas as well. I might upgrade one day... i find if the metal isnt old metal i get pretty good welds, like welding in the new battery tray.
#18
Posted Today, 12:28 PM
yeah my welder doesnt do gas as well. I might upgrade one day... i find if the metal isnt old metal i get pretty good welds, like welding in the new battery tray.
In the scheme of things of doing car rust work, the price of a decent MIG will end up saving you money in the long term.
You will save in terms of time spent, as well as requiring less consumables to dress up the welds you do.
Have a look at a Unimig welder. They are relatively cheap and they are good for the job.
There are a few people who have posted here over the years that started with gasless then bit the bullet and got gas.
Pretty sure every one of the basically went and redid their welds when they saw the difference in quality.
I know I did.
I was trying to do a project on a budget. Ended up costing me more than it should have.
Usually the gasless machines are pretty low quality and they will break down. Then you will find it difficult or impossible to get replacement parts.
Cheers
Rob
#19
Posted Today, 12:43 PM
In the scheme of things of doing car rust work, the price of a decent MIG will end up saving you money in the long term.
You will save in terms of time spent, as well as requiring less consumables to dress up the welds you do.
Have a look at a Unimig welder. They are relatively cheap and they are good for the job.
There are a few people who have posted here over the years that started with gasless then bit the bullet and got gas.
Pretty sure every one of the basically went and redid their welds when they saw the difference in quality.
I know I did.
I was trying to do a project on a budget. Ended up costing me more than it should have.
Usually the gasless machines are pretty low quality and they will break down. Then you will find it difficult or impossible to get replacement parts.
Cheers
Rob
Yeah I don't doubt you Rob.
Here's some more pics...
https://postimg.cc/gallery/jxyLGML
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LJ-1972, Edk