Ian Lanc

Rust!

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Well I took the car for it's MOT and it passed again but this time there was an advisory about slight rust on the edge of the rear sill, I know it's a bit rusty and had every intention to get it sorted, but blimey was I in for a shock! Removed the wheel & wheel arch liner only to see even more rust, luckily there's no rot but if left it would turn into rot, our car looks very decent for a 10 plate, don't let a good looking car fool you into thinking everything is mint, spent the day removing all the rust and repainting it, the part hidden by the liner has been caked in grease, whilst the car was jacked up I also noticed bubbling of the paint, so got a chisel and skimmed off the paint, this revealed rust along the entire length of both sills, the rust was on the underside of the sill, so couldn't really spot it.

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The focus I used to have developed similar rust, especially noticeable blistering all around the top of the wheel arch on both rears. 

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There's a YouTube of an X-Type Jag that looks pretty decent till you see a shot of the underneath. It's fully rotten both lengths of the sills. 

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To behonest I'm shocked to find the rust along the sills, the underside of the sill has a rubbery protective coating, but the rust has started from underneath it, odd this is, so it must be the steel that has been used from the start which has caused this! I can remember Ford buying very cheap steel from one country and this steel contained a lot of salt, so no matter what you did, you'd never stop the rust from rusting inside to the outside, this cheap steel was purchased in the late 1980's early 1990's and many Ford cars suffered with bad rust & rot  early in life, the Escort/Orion/Sierra suffered really badly at the time.

I have seen other newish Fords suffering from rust, even seeing a 09 plated maroon Fiesta which was a mass of rust around the base of the arches on all four wheel arches

Our car hasn't done mega miles, it's a 10 plate and only done 50,000 miles and it's always been kept clean.

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I remember the Lancia Delta of the 70's/80's which would virtually rust before your eyes. Story with that was that Fiat had got a cheap supply of steel, from Russia iirc, which was of very poor qualty.

We had similar rust issues with our old Ka Mk 1 and I heard a similar explanation - that some were built using batches of poor quality steel. Some I see have very little rust, whereas others are in a dreadful state - I have seen one where virtually the whole nsr panel had gone.

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41 minutes ago, Eric Bloodaxe said:

I remember the Lancia Delta of the 70's/80's which would virtually rust before your eyes.

I knew of a guy who owned a pub near Lincoln and he got himself a brand new Lancia Delta Integrale, it was a beast of a machine, but only a couple of years in rust was spotted and no matter what he did, he couldn't stop the rust, then on one MOT test, the car failed because of rot along the chassis rails, he fell out of love & gave up on that car, so stuffed it in the storage section of the pub back yard, over the years as we passed by we could see the Delta gradually getting worse, first indication was seeing the lower plastic sill covers drop off one end, then a few months later the sill cover was on the floor, then one day a back door was dropped down, then a few months later the door was on the floor, eventually it got trailered up and took off to a scrapyard, sad times for many Deltas.

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The Delta Integrale is one of my favourite retro cars, there are still a few about at the shows & meets!  Doubt much of the bodywork is still original by now though!

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2 hours ago, TomsFocus said:

The Delta Integrale is one of my favourite retro cars, there are still a few about at the shows & meets!  Doubt much of the bodywork is still original by now though!

Local to me is a monster of a Delta, it's a yellow 'Giallo Ginestra Special Edition' ...It only comes out his garage no more than 5 times a year....Saddo!!

Not the actual car but exactly the same as this:

 

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I remember an edition of Wheeler Dealers where they managed to find a rust-free Integrale to restore. Nice car! 

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Back to the rubbery coating. I have had mAny cars where the rust has got under the rubbery coating. You press on the coating and feel rust crunching under it. Sometimes it’s like it’s worse because the rubber coating is holding damp in. On my 2007 fiesta rust started creeping under the rubbery coating when 5 years old. You need to do your on checks underneath every year to keep it under control. Most people just rely on mot but if it fails mot on rust it’s been left far too late. 

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1 hour ago, isetta said:

 Most people just rely on mot but if it fails mot on rust it’s been left far too late. 

This is what is BUGGING ME..... Since the car started with it's MOT's & servicing they have all been done at a Ford dealership and every time the paint inspection sheet comes back as being virtually rust free, pictures showing what they'd supposedly checked and passed, they did mention about the slight rust at the end of the sills last year, but it's only surface rust, so nothing to worry about, they said!!! ..... 

This year I didn't use Ford for my MOT and this garage spotted the rust at the ends, then i spotted the severe rust along the lower edge of the sills, there's no way in one year that the rust had developed that badly, so I'm thinking Ford NEVER even bothered to check the underside, nor any of the panels, just ticked the sheet and that was the end of it.

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Get the rust off and paint it. If you are worried about it coming back, treat regulary with ACF50 or XCP's equivalent. 

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2 hours ago, Bolosun said:

Get the rust off and paint it.

Already have matey, inner arches totally sorted out and the hidden seam behind the liner is massed in thick grease, rust on the underside of the sills removed and treated and primed, did a few layers of green paint and then lacquered, but then ran out of green paint about 2 feet long, will fetch some more paint when everything is back to normal.

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I should have taken pics of the sills as they 'was' with the rust on and then 'after' pics without the arch liner fitted & the redone sills.

I've also removed the rust off the trailing arms and repainted them, should look good for a few years now.

Two pics though of one side, a bit happier if i'm honest.

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