This is a very simple piece to repair, when I get home I'll post some pictures of one I did. Much easier to do properly than weld a sheet over to give the appearance of an old car.

Ha! we actually discussed that idea! but I don't think I'd ever achieve a consistent finish overall..



- thanks R, I'd be really keen to see that.

Milde update.

I have left the 3/4 panel for now while I decide what's going to happen with it and turned my attention to the corrosion at the LH rear seatbelt mounting.

What initially appeared to be heavy but localised corrosion turned out after grinding etc to be fairly widespread!

I'd been struggling with loosening the mounting bolt that was seized.


As the bolt become increasingly stuck it began to twist the semi corroded mounting plate and soon the reinforced plate added for the seat belt mounting was itself giving way in the wheel arch!


Looking up = looking BAD:


So I got the angle grinder to lop off the bolt and started to remove the crappy rusty grot.




Oh bumhats!


wire brush on the grinder:

More and more of the car vanishes....




So! this entire corner of the car is really quite rusty!! the rest of the car is very solid - including the opposite rear quarter which seems to have survived solidly. I suppose this LH side has succumbed to the ravages of the 'Gutter side' !

Late, but as promised:





Simply a piece of angle, approx 15mmx15mm welded in and sanded back. The curve at the end was put in by cutting a series of slits into one leg of the angle and curling it up, then welding the slits up and sanding. The curve along the bottom of the window was put in by simply using a rounded hammer and an anvil.

that's my car that's my car that's my car

I love Russ I love Russ I love Russ

every window on my car looks something like yours did before the work... rotten along the bottom of the window... windscreen...back doors... rear windows.... shes gna need a fair bit of tlc before september... mot time.. again

THX what sort of welder were you using for this bit?

Windows aren't MoT fail points.



A really gash 150a Clarke Mickey-Mouse-MIG, throwaway bottle job. IIRC I used 0.8 wire, but have since been using 0.6 which is nicer.

Ok well recently I have started working on the window - not finished yet but the new metal is formed ready for initial fitting:



New metal


Cut to size


First looks


First steps of forming






Then some final test fitting




So when I return I'll carry out the final fitting, bit of trimming and preparing the surrounding areas to weld this in. It took quite a long time to make this repair section so I better not screw up the welding!

Next time dudes

knew that bit russ.... they just look really really shite n tatty... and my back doors actually have no strength at all! you can push them in and out with a finger and im sure after a few more bumps my windows will just rattle themselves loose