ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum

ZUKIWORLD Discussion Forum => Technical Discussion - Beginner / Repair => Topic started by: 1987zukisamurai1.3 on July 20, 2012, 12:48:33 PM

Title: Dealing with rust: Bondo or Fiberglass?
Post by: 1987zukisamurai1.3 on July 20, 2012, 12:48:33 PM

Got an 87 sami, it's been living in florida it's whole life, so naturally the salty air has cause some rust holes in the body.  I'd like to know what you guys suggest as far as bondo vs fiberglass.  I've worked with both, and they're both a pain in the ass...  I just want to know which will provide a more perminant solution and stop the spread of rust! 

If anyone knows of something better than bondo or fiberglass, i'd love to hear it! 

Thanks a million!
Andy E.

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: talonxracer on July 20, 2012, 01:50:42 PM

Cut the corrosion out and weld in new metal, the correct cure.

or

Clean it off, in and out, coat with Chassis Saver in and outside and then back with glass and fill with bondo.

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: kbeefy on July 21, 2012, 02:17:29 PM

POR and steel.

Fiberglass is way stronger than bondo, bondo is more for making it pretty than actually fixing anything.

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: talonxracer on July 21, 2012, 04:41:36 PM

Here is a fix I did on my Kick, a small 1/2" by 3" long hole near the front strut tower.

I cleaned the loose corrosion off, applied 2 coats of aluminum Chassis Saver, then wetted out 2 pieces of 12 oz carbon fiber tape/cloth with the aluminum CS and laid it down over the hole. When that cured I tried to dislodge the fix and it was tight and strong as all heck.

(http://i54.photobucket.com/albums/g96/talonxracer/IMG_1408.jpg)

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: GO_OUTSIDE! on July 25, 2012, 06:46:36 AM

Quote from: talonxracer on July 21, 2012, 04:41:36 PM

Here is a fix I did on my Kick, a small 1/2" by 3" long hole near the front strut tower.

I cleaned the loose corrosion off, applied 2 coats of aluminum Chassis Saver, then wetted out 2 pieces of 12 oz carbon fiber tape/cloth with the aluminum CS and laid it down over the hole. When that cured I tried to dislodge the fix and it was tight and strong as all heck.

([url]http://i54.photobucket.com/albums/g96/talonxracer/IMG_1408.jpg[/url])

I just ordered some, gonna use it on my build! Thanks

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: AKSamurai on July 30, 2012, 09:58:32 AM

Cut out the rust and weld in fresh steel.  Once rust starts you have to cut it out to stop it from spreading.  Fiberglass is for boats and Bondo is for filling door dings.  Do it right if you want to keep the truck.

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: 1987zukisamurai1.3 on July 30, 2012, 11:51:06 AM

I'd love to be able to cut out the offending peices and weld in new metal, but it's just not in the cards.  I have no way to do it myself and cannot afford to pay someone else to do it...

The Chassis saver stuff looks pretty good.  What if i were to cut out the rust, cover the area with a couple layers of CS, Put some carbon fiber tape behind the hole, cover front and back with a couple more layers of CS, then use bondo to smooth over the area?

Also, can i get this Chassis Saver stuff from an autoparts store or does it have to be ordered online?  Same question about the Carbon Fiber tape...?

Thanks a lot guys!

Title: Re: Dealing with rust: Bondo or Fiberglass?
Post by: talonxracer on July 30, 2012, 12:56:10 PM

chassis saver can be found at some auto parts stores, check out the dealer list on the chassis saver site.

Carbon fiber can be found at alot of Marine stores that also carry hull repair products, Epoxy, kevlar, carbon and fiberglass.
http://www.uscomposites.com/carbonpage.html (http://www.uscomposites.com/carbonpage.html)

I removed the fully rusted edges of the hole, making the hole larger and then applied the CS and carbon.