I would love to see a pic of that repair if you have it. Basically, the whole drivers side trunk well is gone on the Squash! I have to be careful what I carry in the trunk as it is big enough for a football to fall out of!




The above discussion is about the firewall, not the battery tray...

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

Mine was not quite that big. See post 8: http://schumanautomotive.com/forums/showthread.php?t=3070&highlight=rust

The same technique could p be used on a larger hole as long as it is not a structural area and there is solid metal to bond to.

This repair was done on the 240D I sold this year and I forgot to take after pictures. Unfortunately the new '85 has the same problem so I will try to do a better job of documenting the repair this time.

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

Thanks for all of the replies, there are certainly a lot of varying opinions on the subject.

I do have access to a welder but the area I would need to do the welding is pretty tight,and wouldn't I have to do a lot of surface prep in the vicinity, de-undercoating etc.?

Even if I welded the area, wouldnt a topcoat of POR15 be a good idea?

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'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car

Im in the process of rust repair also, I have the same hole as your all talking about and havent decided what Im going to do to fix it yet. Welding I would think would be out of the picture unless you pull the dash, the AC box and the insulation off the fire wall otherwise you will have a nice fire, one thing I havent seen anyone talk about is panel glue allot of new cars have glued together parts coat it good with rust inhibitor and glue on a patch should be good as new and sealed up. My big problem was the thing leaked for so long that it rusted out the passengers floor pan a bit so I have to fix all that too but o well its a 20 some year old car its bound to happen