I’m pretty sure I have the rust sorted in the passenger side wheel well. So it was time to reassemble.
What I didn’t investigate was all the ADDITIONAL spot rust. I spent some time arresting rust on the inside of the fender. I also covered the welding spots on the inside of the wheel well. And I got crazy with the cheese whiz, seam sealer, and covered some spots there too.
I didn’t forget the light assembly this time. I did forget the fuel filler door latch. Soooo….I got to do the job twice. I’m getting pretty good reassembling the rear quarter panels!
I nearly forgot that I had to install the mud flap and had to finish that job before I could call it a day. It went together pretty well and was easier to to than the drivers side in my opinion.
With this job done, I am able to concentrate on the rusty B pillar.
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I’m getting real close to finishing the C pillar repairs. I had one final repair to finish. The patch over the rust at the bottom of the C pillar. If you know Range Rover Classics this is where the sunroof drain comes out and runs down the back of the wheel well. This is a popular place for rust to setup shop and eat your precious Range Rover Classic.
So instead of “fixing it” just like it was designed, which was poorly executed. Poorly because they didn’t protect any of the inside surfaces. Poorly because, seriously, holes in a wheel well where water, salt, sand, dirt, animal parts, and just about anything else you can imagine can hide? Super stupid. That sounds harsh, but you shouldn’t design an offroad vehicle that descended from the amazing history of Land Rovers in such a way that you can’t use it in the environments it was designed to live in.
I spent a lot of effort to shape the patch. I also devised a way to hold it in place so I could weld it there. A strategically placed bottle jack and a length of pipe. I called it the trapeze of stupidity in the video. I’ve done dumber things. This one actually worked really well.
After turning up the welder a tad, and increasing the wire speed to compensate the upside downed-ness of this welding. I saw a couple of videos where guys were welding some structural steel and they suggested uping the wire speed and voltage. That seemed to work. My problems were with the primer I painted on the fender and the patch. And at some point I think my ground was not very good. This lead to some very poor welds which I had to grind off…. several times. Eventually I got everything sorted out and the welds started holding.
Once I had the patch in place and covered in primer I took a look at the rest of the rear quarter panel. I cleaned up some surface rust and coated it with primer. I know this is only to slow the rust down but it felt good to do it.
I got all the patches on the quarter panel covered in seam sealer. Everything also got a final coat of primer. Over the primer, under the wheel well, I put on two coats of rattle can bedliner. It is my sincere hope that this will keep some rust at bay for at least a few years.
I have all the wrap up to do now including reassembling the quarter panel and reinstalling the mud flap assembly. That will be the next video. After that, I will be working on the passenger side B pillar.
In this installment I continue patching the rust on the passenger rear wheel well. The patches went pretty well, all things considered. I am learning that i should probably use the zinc weld through primer. The basic primer I am attempting to use prevents me from having solid welds.
I wire wheeled off A LOT of paint to get these welds to stick. Not great considering I need paint of some kind on this metal. I have one more patch to weld on this fender. I will use the zinc primer.
I also replace one of the sunroof drains using some tubing I bought from one of the big box stores. I’m going to come right out and say I don’t recommend this stuff. It had too many pinches in the tubing. I thought I could use a heat guy and get the tubing flexible enough to reshape the tube.
This failed miserably. What did work was using some zip ties to eliminate the pinch. How this worked was the zip ties press equally all the way around the tube. This seemed to work amazingly well. Super happy with that clever trick. So if you can’t find high quality tubing, you can use the cheap stuff and you may need to employ this trick.
Getting this tubing into the C pillar was challenging. If you are patient you will succeed. It took longer than I thought it would to get this tubing in the right place.
As I mention in the video, I needed to cut a hole in the lower part of the C pillar. I decided to direct the tubing down the INSIDE of the fender well. This removes another hole in the wheel well. I will, as I mentioned in an earlier video, drill a hole behind the mud flap and using a pass through pipe thingy I will be able to send that water out while attempting to have a less rust prone way to get the water out of my Classic.
I also learned welding upside down is HARD. I had absolutely no luck getting the final patch to stick. I said in the video I would would watch some videos. Unfortunately I did not find a single video on Youtube where someone was demonstrating welding sheet metal from below or upside down.
I watched a couple of videos of guys welding structural steel joints upside down or from below. The one trick I will try this coming weekend is to increase my wire speed and maybe increase my voltage. Basically being more aggressive. Maybe if I’m lucky it won’t just blow holes in my steel.
That’s all for this week. Like and subscribe to the YouTube channel. Comment as well if you see something I’m doing wrong or could do better. I’m no expert, I’m just winging this like most hobbyists do.
Most of the country is experiencing extremely cold temperatures. It got down to 1.6ºF last night here at Okierover Base Camp. Thankfully the winds were mild (mild for Oklahoma anyway) and the windchills stayed in the minus teens and single digits. Still VERY dangerous to be outside.
That didn’t stop some of my fellow overlanders from going out in this mess. This is not fun camping weather. Changing a tire in this weather can seriously test your constitution. Frostbite is just 15 minutes away in this weather.
Instead I give a short overview of what I called a short-term To-Do List.
Wire for Power in the back for a battery and fridge eventually
Install radio and cameras
Purchase and install a GMRS radio
Fix the Ignition Issues
You’ve heard it all before. My goal is to get back behind the wheel by April. If you don’t set goals, you’ll never achieve them.
That’s all for this week. I’ve got to go take care of Mrs. Okierover who got diagnosed with Covid today. My son is on the downhill slope of Flu A. I’ll be lucky to survive the week without catching SOMETHING!
Wash your hands, thanks for reading and Happy Rovering
The plan this weekend was to do some welding. Unfortunately the welding supply store was closed. So I was unable to source the shielding gas I needed. That…was frustrating. I instead knocked out a project my wife has asked for “she claims” for 18 months. I’ll admit it was a while…but maybe only a year. In any event, the pantry portion of the former laundry room now has fancy shelves.
So today I did some more investigating of the rust, primarily on the A and B pillars at the sill. The B pillar is mostly rusted out. It is as bad as it looks and I’ll need to source the ready made B pillar lower portion. I’ve seen them online…but don’t remember if they are available in the US of A. I’ve found at least three businesses in the UK. Part is only about $33.00(US) the shipping to the US is the same amount. More research is needed, or I weld up my own version.
The A pillar has a hole next to it in the sill. I think it would be an easy patch to fix.
So this week I’ll get some more shielding gas and I’ll be ready to do some repairing next weekend.
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In this post I explore the rust under the passenger side fender well. It was my intension to WELD this weekend. Unfortunately I absent-mindedly did not turn off the shielding gas and the tank was empty. Major bummer.
So I took time to get the fender ready. I also cut my patches. I also installed the new gas tank filler hoses and my new gas cap. How exciting! It wasn’t.
I cut the fender rust out of the part where the body mount is. Turned out it was just the outer skin that had rust. I cleaned up the rusty metal underneath and will paint it with the magic rust-encapsulating-paint before I weld the patch for the fender back in place. Why Land Rover didn’t bother to try and keep rust out of there is still a mystery to me. It’s like they WANT their vehicles to rust out. What kind of a sales strategy is that?
I’ll need to get more shielding gas this week. However there is really NO RUSH because Christmas is this week and the house will be filled with people and very little in the way of rust repair will get done.
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Thanks for reading and Happy Rovering and Merry Christmas from the Okierover family.