Reet...

Ive finally started work on the tailgate of the 1242cc Cinq, all hardware is off: boot lock, rear wiper and rear sprayer now on the parcel shelf

The two huge holes - that being the enlarged bootlock hole (there was a formed section that needed removing) and the wiper hole - are easy enough - remove all paint in surrounding vicinity on both sides, fibreglass the internal side up, fill the external side, sand it all flush, paint the bugger

Problem I have is with the wiper washer hole - its only about 3mm across and access to it is very limited I cant really get into the area to remove paint to secure some fibreglass or other supporting material.

Given the size of the hole, is it really necessary to support the filler from the opposite side?

arseofbox said:

Given the size of the hole, is it really necessary to support the filler from the opposite side?

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Yes! But you don't need to remove the paint just key it up, the fibreglass will stick.

couldnt you use something like expanding foam?fill the hole then remove the excess and flush with filler?

custard boy said:

couldnt you use something like expanding foam?fill the hole then remove the excess and flush with filler?

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I don't think that would work mate As soon as you try to put filler over the top of it it'll probably push the foam out.

Ben R said:

Yes! But you don't need to remove the paint just key it up, the fibreglass will stick.

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Ah right. Thats gonna be a pig of a job to to key then GRP in!!

find some one who welds? wouldn't cost much to weld a hole the size of a 2p coin? circle of mild steel plate, 2 blobs of weld and grind it off? then filler to smooth. Would take me 5 mins? prob cost 25-30 quid from most welding firms?

Look for a company that does agricultural or HGV work, not a bodyshop as they'll charge a ****load. also it's worth finding a welding forum and asking if there's anyone near you who could do it?


Jon

project-cinqy said:

find some one who welds? wouldn't cost much to weld a hole the size of a 2p coin? circle of mild steel plate, 2 blobs of weld and grind it off? then filler to smooth. Would take me 5 mins? prob cost 25-30 quid from most welding firms?

Click to expand...

I could get it welded Free of Charge if I so chose...but the car isnt moving as it has no cooling system, even then, its SORNed.

But on the advice of one of the welders (the guy that was gonna do the boot till I decided that it wasnt out of my skills), access is the problem, so GRP'ing the hole in would be the best action..

1>Anyone got any clever ideas on how I could sand to a curved profile?

EDIT - Right Ive 'glassed the two bigger holes in. That went according to plan

2> Only prob is 'glassing in the smaller hole as access is really tight (eg: I cant turn my two fingers round once in the hole.), the fibreglass just breaks up...so Im gonna need to look into a different way of filling that hole....using some of that aluminium mesh stuff (and some tiger seal to stick it in) isnt that far out of the question...providing I try a dry run first...

EDIT 2 - Solved 2 using Aluminium mesh and chemical metal I hope....

Right. All solved. its all nice and flat now

The entire tailgate has been attacked with P80 through to P240 W+D paper.

Current prob is what primer to use...Is it worth applying a layer of filler primer prior to a normal primer to just iron out any imperfections?