Toyota 100 Series – Front Windscreen

RE:     Toyota Landcruiser 100 Series –  Front Windscreen Aperture (Corrosion Repair)

This document has been prepared with photographic illustrations to highlight the severity of corrosion damage and the recourse of the repairs conducted.

1.0           Initial Inspection – 22/01/19

On the 22/01/19 @ 20:30pm, an assessment was carried out to determine the extent of vehicle damage and to enable an estimate for the repairs to be carried out at the clients residence. From the initial review, a preliminary rectification schedule was compiled and estimated (the basis of the repair scope and estimate was the use of lead filler and two metal plates to fill the large void areas). The photo below illustrates the conditions at which the assessment was carried out (at night and under insufficient lighting).


2.0           Vehicle Review – 24/01/19

The vehicle was delivered to the workshop on the 24/01/19 at 09:30am. The vehicle was reassessed under better lighting conditions and the following observations were noted. The photograph below illustrates one of the void areas where the level of corrosion damage was more significant with the corrosion penetrating through multiple layers of the windscreen aperture.


The second observation noted was that the outer turret skin had separated from the internal support frame. This is clearly visible by the horizontal fracture line of the full length of the windscreen aperture.


3.0           SCOPE OF WORK

From the condition review/reassessment conducted on Thursday 24/01/19, the following scope of work was conducted to meet the basic requirements of the repair and return the structural integrity to the panel section.

3.1                Turret Aperture

In light of the condition reassessment and scope requirements, a complete new panel section was fabricated to match the original profile. The fabricated panel was then trial fitted for the correct contour and alignment.


Note: the multi-layers of corrosion build up beneath the aperture were obstructing the correct alignment of the replacement panel, so the complete lower lip of the aperture was removed.


Upon removal of the windscreen aperture section, the internal support frame was found to be weakened by the corrosion. The area was sandblasted to remove the corrosion contaminants and clean the metal surface ready for welding.


The panel replacement section was aligned and held in position by clecos and then fully welded.


3.2                Vertical Apertures

Both of the vertical apertures were found to have localised areas of corrosion around the perimeter of the (pillar trim) fixing holes.


The full lengths of both apertures were sandblasted to remove all of the corrosion contaminants.

4.0           Conclusion


The remediation of the corroded turret section has been completed above the standard of the quoted repairs. The requirements have resulted in time/cost variations which we have absorb to preserve the integrity of our fixed price guarantee.

René Farrace

Mustang Fastback

Lead Wiped Repairs

The rust repairs/restoration of the Mustang door pictured here has been repaired by a technique called lead wiping. At Auto Resto we are passionate about providing quality repairs and this is why we still practice this old art. This is our way of providing a budget friendly solution and still maintain the quality of a metal finish.

This Mustang is a fine example of a picture perfect vehicle. Although there were some major issues with both the driver and passenger doors. The corrosion in the lower sections of both doors were so bad that they had to be removed to be repaired.

This slide attached illustrates the Mustang door removed from the vehicle and the internal mechanisms completely disassembled. The next step in the process for this door is for all of the corrosion to be removed by abrasive cleaning. Hence the reason why the door is just a shell.

Although sand blasting is the best method to completely remove all of the corrosion deposits, the process can create issues far beyond just the repairs required. For example, if the door mechanism, glass and window regulator were left in the door, the fine grit would penetrate into the mechanism and fowl the operation. If the abrasive made contact with the glass, you can kiss that good bye too! As laborious at it might seem, prevention is far more sensible than the grief, time and cost and of locating & replacing damaged parts or components.

At Auto Resto we pride ourselves with providing quality solutions that endure the test of time.


Holden EJ – Fender

Holden EJ – Fender
This fender belongs to an Holden EJ Ute.

Sometimes a clients budget needs to be staggered over time and we don’t always get to see the whole vehicle all at once.

This fender had some minor issues in the past which could have been repaired better by the other repairer. At first sight, the corrosion appeared to be concentrated at the lower rear section of the fender.

The fender was then sandblasted to remove the paint and corrosion contaminants.
After the blasting process, the fender was reassessed and we found that the upper rear section of the fender had a small concentration of corrosion perforations.

Rene created a pattern of the fender sections and then fabricated the complete external (rear section) and lower internal fenders sections.

The corroded internal & external fender sections were then cut out and the replicated panel sections were fuse welded in place.

This may seem to be an extreme approach, but at Auto Resto we warranty our rust repairs for 5 years. We are passionate about restoring vehicles and eliminating corrosion.