W123 rust repair approaches...

Hi! Have a 240D with the usual rust spots in the fenders behind the front wheels, in the lower part of the driver's door, etc.

Without going the route of replacing whole fenders and doors, what's the best approach to keep ahead of rust? I gather repair panels are not available.

Thanks again for your time and suggestions.

[ymsin]

I find the rear fenders of the W123 most prone to rust, and or course, the lower part of all 4 doors. Rust may also appear beneath those floor mats - which many of us may not be aware of.

The rust at fenders may be a little difficult to do on your own as part of the fender (depending on how rusted it is) may have to be "cut" away.

The rust beneath the doors however, may be saved by first scrapping or sandpapering of the rust, then with anti-rust applied, the lower door-portion can be easily sprayed to blend with the chasis color. This again depends on the severity of the rust.

There is this product in Singapore - or so I was informed by my brother, Kenny - that arrests rusts (electronically). This device emits electronic pulses every so often, from its fixed position in the bonnet and flows to the boot. Kenny reckons it works well as his cars had less rust-problems thereafter. The costs: approximately SGD600-00 including installation.

I am not aware of this product being made available in Malaysia, or the US.

Worth checking it out.

ymsin,

This electronic thing only works if the car is rustfree to start with.

[dakota]

There is an outfit called Restomotive Labroratories that makes a product called POR-15. This stuff really seems to work well. They have several specialized products and systems. See http://www.por15.com/ for more information.

The conventional way as you know is cutting and welding panels, or replacing panels. This is very expensive, and to be quite honest with you, may not be a good choice because if you have a lot of rust, the cost of the repair will be more than what the car is worth.

But anyway, sanding it down till you see metal, then apply the anti rust protecting coats should do well. But try to get as much or all the rust off if you can before apply the anti rust compound.

My 84 300D Turbo, which has 110,000 original miles, and rarely driven is rusting. As usual the bottom end of the car around the rear wheelwell. Another place I noticed it, is in the front of the car, under there is a metal spoiler like, and the hindges might rust. You have to crawl under the car or get it in the air to see it though. Hope this helps you some...

[william rogers]

The only proper and lasting way to take care or rusted panles is to cut out the rusted area clear back to clean meatal and then fit and weld (best done with a mig welder) in new body sheet steel of the right gauge, then the high spots are shrunk and the low spots filled . It's really fun when you get on to it .
William Rogers.....