I de-rusted the rest of the tailgate outer spots and notices some at the bottom edge, internally, under the latch unit where there is a strengthening plate welded on.
I think water has been entering via the latch handle area and running down inside the skin. The construction is such that any water that does enter via the light units, or latch unit drains out of the bottom of the tailgate, however the under the latch area is only primed, no top coated and is made of more than one sheet of steel, so has edges, where paint won't cover well.
I tried scraping and wire brushing this area, but access is extremely limited, with no chance of being able to de-rust completely, so have resorted to using a phosphate rust converter, which converts and encapsulates rust to make it stable and impervious to oxygen.
I have given this and whilst I had it available, also the outer bare patches, three coats of converter.
2 * 2.1 SD
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Dieselman
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Re: 2 * 2.1 SD
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
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90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
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90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
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Dieselman
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Re: 2 * 2.1 SD
At the sides of the tailgate I had noticed one patch each side where the seam sealer had worn away, so I squeezed in some new and then painted all bare areas with two coats of brush painted primer. I'm not bothered about appearance as these are all discrete areas, behind external trims/light units. Brushing means no masking, and a thicker paint coat.
In the internal latch area I also added a single spray coat of primer, to reach any awkward areas the brush couldn't reach.
In the internal latch area I also added a single spray coat of primer, to reach any awkward areas the brush couldn't reach.
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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Re: 2 * 2.1 SD
Time to mix black and blue paint at a 73% black ratio. I made up a total of 68 grammes, (50+28)which was sufficient for two coats.
I chose to use Hamemrite as it is a quick drying and hard paint, so I can rebuild the tailgate quickly and the paint should provide reasonable wear protection.
The machine enamel I have would give a better brush painted finish, but is slower to dry and will take longer before it becomes as hard-wearing.
I painted all touch points, including the ones on the body coloured plastic bar that had rubbed through the original tailgate paint.
I Also painted over where the seam sealer has been replaced as well as some areas where the original paint was still sound, as I want to add additional protection.
I painted the underside of the tailgate as the interior plastic trim had rubbed through the paint.
I recovered the boot tie downs from their acid bath and gave them a final scrub. These were originally very rusty.
While I had, clean, left over acid I scrubbed the rubber glass trim, which was encrusted with so-far, impossible to remove lichen. Not quite gone in sixty seconds, but pretty good.
You can also see in the below image the fresh paint around the spoiler mounting holes. The paint is a good colour match, but isn't metallic, but it doesn't matter as it is under the spoiler foot.
I chose to use Hamemrite as it is a quick drying and hard paint, so I can rebuild the tailgate quickly and the paint should provide reasonable wear protection.
The machine enamel I have would give a better brush painted finish, but is slower to dry and will take longer before it becomes as hard-wearing.
I painted all touch points, including the ones on the body coloured plastic bar that had rubbed through the original tailgate paint.
I Also painted over where the seam sealer has been replaced as well as some areas where the original paint was still sound, as I want to add additional protection.
I painted the underside of the tailgate as the interior plastic trim had rubbed through the paint.
I recovered the boot tie downs from their acid bath and gave them a final scrub. These were originally very rusty.
While I had, clean, left over acid I scrubbed the rubber glass trim, which was encrusted with so-far, impossible to remove lichen. Not quite gone in sixty seconds, but pretty good.
You can also see in the below image the fresh paint around the spoiler mounting holes. The paint is a good colour match, but isn't metallic, but it doesn't matter as it is under the spoiler foot.
You do not have the required permissions to view the files attached to this post.
91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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- Joined: Thu Jun 18, 2009 6:44 pm
Re: 2 * 2.1 SD
I remounted the external fittings onto the tailgate and wanted to ensure no water could enter.
The tailgate metalwork has an extra internal layer behind the lower lights, that is designed such that any water entering will be directed to the base and out of the drain holes and judging from the rusty screws inside the tailgate and water found in the boot, water has been entering. On opening the tailgate any water left in this layer will run inside the boot inner trim panel and then into the boot.
As well as fitting new rubber spoiler seals, I have used non-setting Butyl mastic on all areas I think may have leaked. The spoiler seals are an obvious place, but I also think the painted plastic trim fixing screws have been leaking water in.
Additionally, water runs behind the upper light-bar, down the tailgate and inside via the latch handle area, which doesn't have the additional funnelling metalwork.
Spoiler seals, including mastic.
The latch handle sits in a large A shaped hole with a rubber seal. To ensure the seal doesn't leak internally I added mastic into the rebate, before fitting it into the hole. It clips round the metalwork, so when water enters this seal at the top, it can migrate from the outside to the inside as it runs down the vertical section.
The latch handle simply abuts the rubber seal, but is covered by a plastic hood, which is part of the painted trim panel.
Normally one fits the painted trim after the lights and light bar, but I wanted to add mastic so fitted it first.
Mastic round the screw holes and the A shape that should tightly press on the rubber seal face. I was concerned there is insufficient pressure to create a reliable seal.
I added additional mastic once the panel was installed. I believe this is where water was leaking in and really want to keep any water on the outside of the panel.
Refitting the tailgate lights meant undoing the painted trim panel screws, apart from the ones round the latch unit, to allow the trim to be flexed out, allowing the lights to pass underneath.
Tip: If painting the inside of the tailgate use a light colour/white. I painted it in dark blue body colour and it made it difficult to see the screw holes for the painted trim panel.
When refitting the latch unit and light units I greased all moving parts and electrical connectors.
I'll monitor the boot for water intrusion before refitting the linings, however judging by the rust on the inner tailgate metalwork, by the boot latch, do think the water ingress has been these areas.
As an aside, I've always been aware this car has suffered with a lot of tailgate glass internal condensation, which I now think is due to this water leaking in.
I always thought it was due to the sunroof, but maybe not all is.
The tailgate metalwork has an extra internal layer behind the lower lights, that is designed such that any water entering will be directed to the base and out of the drain holes and judging from the rusty screws inside the tailgate and water found in the boot, water has been entering. On opening the tailgate any water left in this layer will run inside the boot inner trim panel and then into the boot.
As well as fitting new rubber spoiler seals, I have used non-setting Butyl mastic on all areas I think may have leaked. The spoiler seals are an obvious place, but I also think the painted plastic trim fixing screws have been leaking water in.
Additionally, water runs behind the upper light-bar, down the tailgate and inside via the latch handle area, which doesn't have the additional funnelling metalwork.
Spoiler seals, including mastic.
The latch handle sits in a large A shaped hole with a rubber seal. To ensure the seal doesn't leak internally I added mastic into the rebate, before fitting it into the hole. It clips round the metalwork, so when water enters this seal at the top, it can migrate from the outside to the inside as it runs down the vertical section.
The latch handle simply abuts the rubber seal, but is covered by a plastic hood, which is part of the painted trim panel.
Normally one fits the painted trim after the lights and light bar, but I wanted to add mastic so fitted it first.
Mastic round the screw holes and the A shape that should tightly press on the rubber seal face. I was concerned there is insufficient pressure to create a reliable seal.
I added additional mastic once the panel was installed. I believe this is where water was leaking in and really want to keep any water on the outside of the panel.
Refitting the tailgate lights meant undoing the painted trim panel screws, apart from the ones round the latch unit, to allow the trim to be flexed out, allowing the lights to pass underneath.
Tip: If painting the inside of the tailgate use a light colour/white. I painted it in dark blue body colour and it made it difficult to see the screw holes for the painted trim panel.
When refitting the latch unit and light units I greased all moving parts and electrical connectors.
I'll monitor the boot for water intrusion before refitting the linings, however judging by the rust on the inner tailgate metalwork, by the boot latch, do think the water ingress has been these areas.
As an aside, I've always been aware this car has suffered with a lot of tailgate glass internal condensation, which I now think is due to this water leaking in.
I always thought it was due to the sunroof, but maybe not all is.
You do not have the required permissions to view the files attached to this post.
91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White