Bulkhead rust repair!

Hi folks,
My 110 has a hole in the bulkhead on either side from rust and I won't be changing the bulkhead but will use those weld in sections later, so what would be the best way to tidy it up and stop it from getting worse for the moment.

Was thinking of some sort of rust killer paint and then body filler?

Apply some POR 15 until you can get round to welding in some sections. Lift your windscreen and check under there as this area is prone to rot!

Don't worry everything is doable!!

Was thinking of using some sort of expanding foam on both sides to fill the void and stop the water getting in.

MOB993 said:

Was thinking of using some sort of expanding foam on both sides to fill the void and stop the water getting in.

Click to expand...

that will absorb moisture and make it rot quicker, Replace with new steel. If you cant at the moment spray inside with under coating, wire brush the steel and use a good primer

MOB993 said:

Was thinking of using some sort of expanding foam on both sides to fill the void and stop the water getting in.

Click to expand...

thats not a good idea,when it does get welded you have a highly flammable material in your bulkhead ,plus it will go where not intended to

I was intending on using a foam like what's used in wall cavities etc. It wouldn't absorb moisture. But quite possibly it would be flammable..

MOB993 said:

I was intending on using a foam like what's used in wall cavities etc. It wouldn't absorb moisture. But quite possibly it would be flammable..

Click to expand...

would that be 1/2 pound foam or 2 pound spray foam?

Not sure what it is but seen the stuff before.
What causes it to rust in that particular spot?

So I've been looking into getting my own mig welder and doing the repair myself but the repair sections available from yrm are for the front and wont actually cover the rear where the hole is. Is there much point in getting the repair panels then.

Also is there a guide on how to do it? I did see some lads on youtube muck around and weld a bit but nothing informational..

you need to pull the rubber and see how bad it is and if it goes behind the dash.

then grinder with wire brush on and strip it back. chop out rot, cut shape from new metal and weld it in.

Not a 'how to' as such, but here are a load of photos showing how I repaired my bulkhead with rot in similar places.

Bulkhead

Cheers arc. I'm only learning to weld and don't want to get in over my head then have pay someone to call out to me to finish the job.

The repair panels are iseful for giving you the correct angles but it seems like most people just pop rivet / silicone them on top of the rust.

As already suggested, you need to see how bad it is and how far it extends. And when you're ready to take the plunge, chop away until you hit good metal, get a sheet of fresh steel plate and chop it to pattern with a jigsaw. You'll want to practice welding first! And bear in mind you cannot weld to rust - it'll just vaporise!