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Old 03-30-2012, 02:24 PM   #16
e30tOny
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Quote:
Originally Posted by Nerk View Post
interesting... never thought of plastic... hrmm...
Ya...you could also use in full or combination:

Dual compound fast drying epoxy/steel sticks

you can smooth the stuff at early stages with water,

it's the greatest all purpose stuff I have ever had the pleasure to use

http://www.polymericsystems.com/epox.../faststeel.htm

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Old 03-30-2012, 02:33 PM   #17
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Yeah, lots of solutions. I just wanted to avoid drilling into the metal. On my current E30, I treated the area with POR-15 even though it wasn't bad but fortunately the rubber receivers are intact, I can use the factory fasteners.
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Old 03-30-2012, 02:35 PM   #18
e30tOny
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you can use this stuff too....all this stuff available at "crappy tire"....stick & patches <<<<<$20
you can even tap screw threads into that "steel epoxy" stuff

cheers
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File Type: jpg body patch.jpg (90.0 KB, 48 views)
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Old 03-30-2012, 03:32 PM   #19
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everything you need is available out there. you just need to be a little handy and creative. The longer you spend on it, in most cases the better the job turns out. :-)
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Old 04-22-2013, 01:46 PM   #20
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Sorry to resurrect an old thread but this is exactly the fix I'm working on for my e30. Nerk, did you end up finishing the job? How did it turn out? Any pics?

Unfortunately in my case, the holes for the lights rotted out beyond the outside edge of the new gaskets I'm putting in, so I'll need to patch this somehow to look nice.

I have the Bondo kit pictured earlier in the thread with the steel mesh filler piece. Just not sure how easily I can put that over the hole and leave a nice opening for the lights and screw holes.
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Old 04-22-2013, 02:03 PM   #21
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Try my ABS trick that I posted. You could use anything of that sort, and it will look a lot prettier than slapping in bondo and mesh. Just be sure to treat the rust completely before doing anything.
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Old 04-22-2013, 02:28 PM   #22
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Yup, worked out quite well actually...

I did get some custom paint match done since the previous owner had it painted to not an original colour, but essentially what I did was created some shims to go inside of the trunk, used some rubber cement glue to hold them in place, then I used some plastic filler to make the outside edges smooth, primed and paint, screwed in some new lights and done...

I'll post pictures when I get home from work...
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Old 04-22-2013, 02:29 PM   #23
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and yes... treat the rust! or it will just come back....

I cleaned as much as I can, then used some rust converter in the tight spots where I couldn't get to.
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Old 04-22-2013, 02:30 PM   #24
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I think I can visualize what you're suggesting. Rather than a single piece with a hole cut for the light housing, you used 4 shims on all 4 sides and left a hole in the middle the right size for the housing?
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Old 04-22-2013, 02:45 PM   #25
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Quote:
Originally Posted by everlast View Post
Try my ABS trick that I posted. You could use anything of that sort, and it will look a lot prettier than slapping in bondo and mesh. Just be sure to treat the rust completely before doing anything.
Do you have any pics of your ABS trick? Where did you get the flatstock ABS?
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Old 04-22-2013, 02:48 PM   #26
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I sold the car years ago. I used ABS plastic from a cut up garbage can.
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Old 04-22-2013, 02:54 PM   #27
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uhmm... just 2...
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Old 04-22-2013, 04:35 PM   #28
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ok got pics...

here's the before...



Here's the shim installed with some rubber cement



Here's some plastic filler to make smooth edges on the outside



Primed...



painted...



finished product

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Old 04-22-2013, 04:50 PM   #29
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Very nice! I believe I will follow your lead. Was it Bondo that you used to smooth out the edges?
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Old 04-22-2013, 05:10 PM   #30
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I think it was called liquid metal or something...

Also, I made my own shims with sheet metal, not sure how those ones that were pictured earlier in the thread worked, but I know with mind, its not quite a 90 degree angle...

anyhow...

with a dremel, some patience and a vice, they're very easy to make...
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