Hi,

the D/S hood hinge pocket on my 85 w123 has a small amount of rust in the seam, just to the rear of the drain (it is actually the seam that makes up the rear part of the drain from the hinge pocket).

The problem is that the metal in the hinge pocket is all fresh and strong, no problems. However, the water has sat below that, making a small spot that has opened to the inside of the car. Thus, when it rains and water goes through the drain, some dribbles out the rust bubble and into the D/S front floorboard.

I need to fix this ASAP. I have prodded around a LOT after removing everything I could from under the dash, and have noted that the bubble and soft areas are small.

What I would like to know is, how can I best seal the seam up top in the hinge pocket, so that water does not get in? I was thinking of using JB Weld or JB Stick, since the paint is 100%, the metal is strong and has no signs of crumbling or rust, etc. Would that work, or what would you reccomend?

For the inside, Since it will then be sealed from water ingress from the seam, I will plan to grind/wear away all of the metal that has the rust bubble, down to fresh metal, and then patch it. Since it is on the inside and all the metal around is sturdy, I thought that perhaps a POR patch with fiberglass would be OK. Not that Id use such a thing on more structural elements, but a 2" bubble near the hood release cable, with strong metal all around seems to be a good candidate, especially since it would be super hard to weld in metal in such a small piece in such a tight area.

Of course if after grinding and removing, I see to the outside, then Ill have to think twice, and would likely pay to have the fender removed and the metal welded in from the outside, to which I can finish it, rustproof, POR-15 it, etc.

Any comments on this task? I want it to be done right, and fortunately I have found it early enough it seems, that the metal around is still strong, but Id love any advice you can give, especially about sealing the seam in the hinge pocket, and an internal, over metal POR-15/fiberglass patch.

Thanks!

JMH

P.S. If the hood hinge pockets are tight and in good condition, would it be prudent (provided none of the drain holes are plugged up in the process) to spray these areas with either spray-in bedliner or spray undrcoating? These spots get a LOT of water, and not the best airflow or drying, plus they do get dirty, which doesnt help... I figure with a really good cleanup, paint and then coating with a protective substance, it could really help to protect and seal them better... Your thoughts???

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Current Diesels:
1981 240D (73K)
1982 300CD (169k)
1985 190D (169k)
1991 350SD (113k)
1991 350SD (206k)
1991 300D (228k)
1993 300SD (291k)
1993 300D 2.5T (338k)
1996 Dodge Ram CTD (442k)
1996 Dodge Ram CTD (265k)

Past Diesels:
1983 300D (228K)
1985 300D (233K)

I see nothing wrong with the procedures you have come up with. Since, as you say, it is not a load bearing area, or structual part, go ahead. The bed liner spray is some good stuff. Might be a bit of overkill though.

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95 SL500 Smoke Silver, Parchment 64K
07 E350 4matic Station Wagon White 34K
02 E320 4Matic Silver/grey 80K
05 F150 Silver 44K

I had a rust problem start in the hood hinge pocket a few years ago. I
used jasco paint stripper and got every thing cleaned up in there. was
time consuming, took a few days. then used POR Metal Ready soaked in
some rags, got to keep them wet and it will disolve the rust. just follow
the directions. It was over kill the way I did it, but wanted to make sure
no problems later on.
Also below that drain area it drains out under the car, and make sure you
don`t have a rust issue there also. under the fender where it drains, is a
tube that comes down about 3 inches. the bottom is blocked off. I cut
mine out, and it was packed with debris and couldn`t drain.I just took out
the plastic shield, made it easier. about 6 screws hold it in.
If you take out the shield, check behind the fender towards the door.
could have rust lerking in there also.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

I would guess this problem originally starts from the drain holes at the lowest part of the pocket getting plugged with leaves and crud. Every so often when washing my car, I'll spray water in there to keep the drains clear. So far it has worked, and my car's 30 years old.