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Thread: DIY rust repair around filler cap

  1. #1
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    Default DIY rust repair around filler cap

    Hi - wonder if anyone would be able to share their knowledge on this, wife has a Ford KA with a very common problem of rusting around the filler cap.

    As soon as I got the car a couple of years ago I cleaned all the crud out from under the wheel arch and around the filler cap / neck on the inside and painted with Hammerite - I'm pretty sure this has slowed things down a bit. But now it come through and I need to sort this, I've had a few quotes from garages to get the section cut out and resprayed and I can't really justify spending a small fortune on this bearing in mind how much the car is worth.

    So I want to attempt a DIY fix and would like to hear from anyone that has actually done this - I know I'm never going to get a perfect finish or solution but if someone could point out the steps, tools and bit's n pieces I need it would be greatly appreciated.

    Below are some pictures of the affected area:

    ka1.jpgka4.jpgka2.jpgka3.jpg

    Thanks - J.

  2. #2
    Ex-Staff Full Member John LE's Avatar
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    Vehicle : Facelift Insignia/Corsa D

    Trim : LE/VXR

    Engine : 2.0 cdti/1.6 Turbo

    Year : 13/07

    Default

    Tbh you could stick as much filler in there as you want but it'll just come back within 6 months or so. How much were you quoted to get a panel welded in?

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    £750 from a garage local to me and £1100(!) from a Ford bodyshop, tbh the Ford bodyshop said these were a real pain and take a lot of time to get right. Problem is at that price on a car that's probably worth £1000-£1500 it's hard to justify spending it. If I get time to take it somewhere else to get a quote I will.

  4. #4
    Regular Member Ziggy's Avatar
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    Vehicle : Saab

    Trim : 9-3 Vert

    Engine : 2.0

    Year : 2000

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    Lots of this on the ka owners forum. Im just about to sort it on my sisters.

  5. #5
    Ex-Staff Full Member John LE's Avatar
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    Vehicle : Facelift Insignia/Corsa D

    Trim : LE/VXR

    Engine : 2.0 cdti/1.6 Turbo

    Year : 13/07

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    Ouch! I can see why you'd want to fill it now lol

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    Regular Member Ziggy's Avatar
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    Vehicle : Saab

    Trim : 9-3 Vert

    Engine : 2.0

    Year : 2000

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    Im considering seeing how much a new panel is given she has also dented it.

    Or theres these http://www.ebay.co.uk/sch/sis.html?_...d=130533868784

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    Yeh posted on the KA forum as well, but not as many people on there! The replacement panels are the common way to fix this ... I can only assume that Ford started to do these as so many KA's are like mine. Obviously trying to do the replacement panel is not going to be possible for a DIY'er unless you happen to have a garage full of tools to do it properly. It has been mentioned to cut out the affected small areas of rust and use a rush inhibitor and fibreglass / filler to patch up - appreciate this is not going to be a long term solution. Basically not sure what to do with it now ...

  8. #8
    Regular Member chewy71's Avatar
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    I was going to suggest similar to Ziggy,.. fit an aero type filler cap to hide the rust then part ex or trade or sell

  9. #9
    Regular Member DTi Elite's Avatar
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    Vehicle : Vectra

    Trim : Elite

    Engine : 1.9 cdti 150

    Year : 2007

    Mileage : 145k

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    any repair in this area needs to be welded as it is within 30cm of seatbelt mounting .

  10. #10
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    Quote Originally Posted by DTi Elite View Post
    any repair in this area needs to be welded as it is within 30cm of seatbelt mounting .
    oh, it just gets better this!

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