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Hi.These days the rear window flange in my 63 Galaxie is beeing grinded down. Old bondo, paint an rust are soon gone. This car is over 50 years old, so it could be worse than this, but some rust holes appeared. Its mainly in the corners, the only corner thats rustfree is the upper one on the psng side.
Is welding the only durable solution, or will epoxy/filler/bondo also be useful?
Is there any "corner sections" for sale, that will fit great in the corner areas after cutting away the old rusty ones?
The old window and a new gasket be used, the reason is that the window gasket was leaky, and the trunk was really wet after rain showers. Advices and opinions would be great
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welding is the best option but if all the rust is removed AND the steel is solid around the holes you could use fiberglass. If I was doing it and didn't have access to a welder I would start by using lock tight or other brand rust treatment on the steel. then I would attach a piece of woven fiberglass cloth to the back side of the hole as it is stronger than fiber mesh cloth. From there I would apply resin and add mesh cloth to build up the fiberglass in the holes. Like I said not the best fix but a fix that can be made to work.
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The image attached to this post is the upper corner on drivers side. Brass is used, probably many years ago. Maybe brass could be used now also, using a 300 watt soldering iron and flux
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That is braising, its welding with an acetylene torch. Its a lot harder welding to do than MIG. A soldering iron would never get the job done.
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Yep, looks like brazing to me, which is oxy/acetylene welding with a brass rod, so it is indeed brass. Very old school. Another old school technique was 'leading', which is using wooden paddles to shape melted lead, similar to the way bondo is used today.
I have a few spots like that on my '67, which I plan on patching with sheet metal using a MIG welder. My little Hobart welder is invaluable, even a cheaper wire-feed welder would be a big asset for anyone who does body work on a semi-regular basis. Using fiberglass will indeed work, but if I were you I would find someone with welding experience or borrow a welder and learn 'on the job'. Spot-welding small patch panels isn't that difficult even for a beginner. Having a fiberglass repair would bug then heck out of me even if it were hidden... but that's just me & my OCD talkin'.
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Im not gonna use fiberglass, the car will be brazed or welded
Today I have called to different shops, one of them may do the jobb for me. But I also called a friend, he could maybe help me, we are gonna take a look at the car first. Another alternative could be buying a oxy/acetylen set like this and learn how to use it.
But it may be too hot
A welding course to the winter would be beneficial, for similar problems in the future
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Glad to hear you are going with welding. Do it right the first time to avoid issues later. Problem with rust is that it always seems to creep back. So although fiberglass is a good temporary fix, the rust most likely will return in those problem areas where water and humidity collect and you end up with the same problem later.
Be very careful with welding. Sometimes, there is hidden rusted areas on the other side of the metal you can't see, that will burn or open up during welding. So what begins with a small hole, could end up "burning open" during welding. Further, the rusted areas you have cleaned up are thinner now, and are susceptible to burning through. I have learned that what appears to be a quick repair sometimes develops into a more extensive repair job. You may end up "patching in" some metal to repair those holes.
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I totally agree, fiberglass is NOT the best option. I was just responding to your original question of "Other solutions than welding? " and fiberglas is probably the best option that is NOT welding If you are going to make an investment I would get a wire feed welder with argon/CO2 tank rather than =15pxoxy/acetylene torch. You will find far more uses for the welder than the torch IMHO and with a wire feed welder and shield gas you can learn the welding your self. Its far more forgiving than trying to braze the holes closed. I taught my self to weld on a Lincoln weld pack 100 and then upgraded it to gas and never looked back.
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I agree that an oxy-acetylene torch is not the best option for what you're doing. And those little tanks on the mini-torches don't last long at all. I have a full size oxy/acetylene outfit and I use it mostly for cutting and heating up stubborn nuts & bolts. I do the majority of my welding with my Hobart 140 MIG/flux core unit.
For a beginner I would recommend doing what Daze did and start out with a simple & inexpensive wire-feed flux core welder like this:
That one doesn't use argon gas, which means you will have some popping and spatter, but the welds can be cleaned up with a grinder and it works fine for patch panels where you are mostly spot welding. My Hobart has argon but I don't always use it in order to save on gas. Later on if you find yourself welding on a regular basis, you can upgrade to an argon MIG welder as Daze did.
The best way to fix areas like in your pics is to cut out the entire sections where the metal is thin and there are numerous holes. Then cut & shape sheet metal patch panels to weld in. As mentioned, simply trying to fill the holes in usually results in bigger holes.
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I need to pick up a smaller welder myself. I can go to my buddy's shop and use his, but he has to run a business and I might be in the way.
Eastwood had a nice welder for about $280 that I like. My welder at home is a Lincoln 225, like using a sledge hammer to kill ants.
The smaller holes could be brazed up with a good torch set up. I did some brazing on my oil pan with Harbor Fright brazing rods and it came out good.
Last edited by BOBSS396 (July 16, 2016 7:27 am)