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Preventing known rust spots

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20 Aug 2022 09:26 #244644 by Chris38
Looking at the Showroom condition 2003 listed below has reminded me of a question I keep meaning to ask.
I would like to rebuild a jimny to a good spec which would probably involve replacing the headlight panel and repairing other rust traps.
Most places I can see that a good paint covering and rustproofing would protect them from happening again.
Under the headlights is a different matter as its a known moisture trap. What would be the best way of future proofing that area. I'm thinking drill drainage holes or remove/alter the plastic wheel arch trim.
Anyone got any ideas or cunning plans.
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20 Aug 2022 09:57 #244646 by Scimike
Replied by Scimike on topic Preventing known rust spots
The Jimny headlamp rust feature is not a moisture trap as such, it's just rotten (excuse the pun) design.

They allow water through a structure that is constructed of 3 spot welded metal seams. It's impossible to apply seam sealer in this area to prevent water entering the seam, so it relies on primer paint that may, or may not, have made its way to this part of the panel.

That's why some rot and some don't. They rot from below within this 3 metal sandwich, then emerging just below the headlamp at which point the complete mount is shot.

A total redesign to remove this flaw is the only true fix, but failing that keep this area pumped full of a cavity wax.

Yokohama Geolanders, Sony head unit, NAUTILUS Air Horn, DRL conversion, Rear cargo space, Elvis Bobblehead, transfer Guard, Indian hanging Elephant, Koni Heavy track dampers, Custom SS exhaust, Voodoo Doll, Adventure Rack with LED ight bar, vintage ERIBA caravan usually attached (yes it's slow)

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21 Aug 2022 14:12 #244667 by Chris38
Replied by Chris38 on topic Preventing known rust spots
Brilliant info thanks. So if I do fit a new panel, paint and wax oil to death.

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21 Aug 2022 15:10 - 21 Aug 2022 15:11 #244668 by Scimike
Replied by Scimike on topic Preventing known rust spots
Yes that's about as good as it gets.
If I ever fit a new front panel I would fill the chassis section with anti rust paint, slosh it around and drain. I would also paint any hard to reach places before it is fitted. Weld in place, paint again over the welds, seam seal if required then top coat.After this inject cavity wax into / on everything that's rusted before, keep any drain holes clear.

Yokohama Geolanders, Sony head unit, NAUTILUS Air Horn, DRL conversion, Rear cargo space, Elvis Bobblehead, transfer Guard, Indian hanging Elephant, Koni Heavy track dampers, Custom SS exhaust, Voodoo Doll, Adventure Rack with LED ight bar, vintage ERIBA caravan usually attached (yes it's slow)
Last edit: 21 Aug 2022 15:11 by Scimike.

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