E30 battery box repair help wanted

[CMart]

Keep us updated.

[Boris3]

Will do.

Front part of the box is solid, started digging into the rear pulling out loose paint and metal and the hole kept getting bigger. Joys of rust.

[johnprusinski]

Here is what I came up with.

I can weld, but they do not look pretty. They are strong though. I was standing on it the other day while I was taping my rear window. I can see if I still have the template and I can see if I can create something.

[Boris3]

Wow. No doubt that you could stand on it. That is one serious box!

My battery well has enough metal that I don't think I need the full box insert. I'm looking for more of a repair of the back end of the well.

[johnprusinski]

Since I am not a professional I still like to take my time with things to make sure they are done half way decent. I'm assuming that you don't have a welder, and in order for me to fix the rust I will have to have the car at my house. That's where the problem is. I simpley don't have the room to keep another car at my place to work on. It's easier for me to just work on my bench with a new box insert and then take a day cut metal out and weld it in the car.

[Boris3]

Understood.

Yeah, welding has been on the learn to do list for a while and hasn't happened.

I'll hold off on the full box option but appreciate the offer.

[Rowleym]

Do you have an air compressor? 

I have a portable welding service if need be, but It would be interesting to do without my tools available. 

If possible, I could bend up the required section before I came, and then cut/weld to fit at your place. 

also, My tig is the only portable welder i have, unless you have 220v. 

I live in Princeton WI now. About 30 minutes west of fond du lac.

[Boris3]

I ended up going for the hack route. Did a bit more cutting, sprayed some rust reformer (yeah I know por-15 would have been better), cut and bent some sheet metal to fit, drilled for rivets, primed and an initial paint coat on the new piece.. Need to pick up some seam sealer. Should be able to finish up tomorrow. Install, rivet, seam seal, paint the inside, and undercoat the outside. We'll see how it turns out.

[Boris3]

Some progress. Need to wait 24hrs for the seam sealer to dry before painting the battery well and undercoating the outside.

[Boris3]

Done, now just need to let it all dry.

[B C]

Form follows function. Looks good to me!