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KA body rot  Rate Topic 
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 Posted: Thu Jan 28th, 2016 09:24 am
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Clifford Pope
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Mana: 
A general but relevant question - does the 30 cm rule mean in a straight line through air or the shortest route along metal? They might be considerably different if a hole is in an outer wing.

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 Posted: Thu Jan 28th, 2016 09:23 am
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Clifford Pope
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Mana: 
A general but relevant question - does the 30 cm rule mean in a straight line through air or the shortest route along metal? They might be considerably different if a hole is in an outer wing.

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 Posted: Mon Jan 25th, 2016 06:48 pm
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Stealth
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castrolrob wrote:
feel free to ask on any website that deals with kas,the corrosion problems are horrendous,they are amongst the worst cars we test,generally when the wing gets that bad the underside(unless previously repaired) will be pretty bad,main problem areas are inner/rear wheel arches,inner+outer sills,front chassis above subframe mounts,rear chassis above the beam axle mounts,rear inner sills behind said beam axle(the bit you refer to with the cables attached)rear flitch plates behind the bumper(visible from the wheel with the rear suspension hanging then look upwards)rear top strut mounts,floors around the seat mounts(the reinforcing plate with the bolt poking thru)door steps roughly level with the sealing strip.keep in mind that this aint an exhaustive list,its just the most common points.fail criteria are holed or weakened by corrosion within a prescribed area,even a small hole or split is a fail.

Yup. I inspected one a few years back with most of the above defects present along with worn out trailing arm bushes...........and a brand spanking new Test Certificate !!

:shock:

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 Posted: Mon Jan 25th, 2016 06:07 pm
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castrolrob
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Mana: 
feel free to ask on any website that deals with kas,the corrosion problems are horrendous,they are amongst the worst cars we test,generally when the wing gets that bad the underside(unless previously repaired) will be pretty bad,main problem areas are inner/rear wheel arches,inner+outer sills,front chassis above subframe mounts,rear chassis above the beam axle mounts,rear inner sills behind said beam axle(the bit you refer to with the cables attached)rear flitch plates behind the bumper(visible from the wheel with the rear suspension hanging then look upwards)rear top strut mounts,floors around the seat mounts(the reinforcing plate with the bolt poking thru)door steps roughly level with the sealing strip.keep in mind that this aint an exhaustive list,its just the most common points.fail criteria are holed or weakened by corrosion within a prescribed area,even a small hole or split is a fail.

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 Posted: Sun Jan 24th, 2016 07:47 pm
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wakey1512
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For those who are interested in the current state of the corrosion here is a picture from google which is most similar.



The only difference in my instance is that the corrosion is nearer the bottom of the filler rather than the left.

Obviously the rest of the car such as most of the underside isn't GREAT but no prescribed area feels too shabby yet with thumb pressure and brake pipes are tidy too.

If anything it seems likely to fail on the rear sill N/S where the handbrake cable passes it in the future.

I inspect ford vans which also lack substancial underseal from factory up to about 2009 or so. Disgraceful.

Last edited on Sun Jan 24th, 2016 07:49 pm by wakey1512

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 Posted: Sat Jan 23rd, 2016 01:27 pm
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castrolrob
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Mana: 
have asked the same question,what about drain holes in sills etc.read the manual guys,you are supposed to"pay particular attention to the areas around drain holes etc"as stealth said prescribed areas have been in for about 25yrs now,this aint nuffin new

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 Posted: Sat Jan 23rd, 2016 08:21 am
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Stealth
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skootashaun wrote:
This goes against everything my VE taught me 15+ years ago, and the refesher courses.

 

If a Mk2 escort has rust holes around the ariel hole in the wing (welded on wing for arguements sake) and the ariel is within 30cm of the strut mount, that makes the outer wing fail??


The rules on corrosion haven't altered much in the 27 years I spent in the trade Shaun.

We accept manufactured holes such as the ariel hole, but yes if that area is now corroded in a welded on wing, and it's within 30cm of a prescribed area it's fail.

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 Posted: Thu Jan 21st, 2016 10:57 pm
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skootashaun
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wakey1512 wrote: 2006 Ford Ka with the usual rot around the fuel cap. In places it has gone through. Fuel cap and filler is secure but corrosion is 30cm from a prescribed area (upper shocker mount)

Is it failable?

Can we get a picture just to be clear please  :-)

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 Posted: Thu Jan 21st, 2016 10:55 pm
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skootashaun
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Mana: 
This goes against everything my VE taught me 15+ years ago, and the refesher courses.

 

If a Mk2 escort has rust holes around the ariel hole in the wing (welded on wing for arguements sake) and the ariel is within 30cm of the strut mount, that makes the outer wing fail??

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 Posted: Thu Jan 21st, 2016 05:25 pm
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Stealth
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skootashaun wrote:
Are we talking the outer wing, welded or bolted is an outer wing actually supportive to the shock/seatbelt.

Bolted panels are not considered to be supporting panels. Welded sections ARE considered as supporting panels, giving strength and rigidity in a monocoque chassis. The corroded KA panel is a fail I'm afraid.

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 Posted: Thu Jan 21st, 2016 11:20 am
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skootashaun
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Mana: 
Are we talking the outer wing, welded or bolted is an outer wing actually supportive to the shock/seatbelt.

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 Posted: Tue Jan 19th, 2016 09:03 pm
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Stealth
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castrolrob wrote:
its a monocoque yes?this means that all of the structure is mutually supportive.if its a component that could be simply unbolted than it wouldn't generally count as part of the supporting structure but that's not the case on a ka.get a tape measure out and look,if the strut mount/seatbelt mount(normally the inertia reel mount in the boot) etc is within 30cm(or 12"in old money)which from memory it almost certainly is its a fail.as mentioned below the only acceptable repair is either a replacement panel or a fully seam welded patch repair.sorry,no nosh or filler allowed...

Likewise. It's a supporting panel.

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 Posted: Tue Jan 19th, 2016 06:00 pm
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castrolrob
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Mana: 
its a monocoque yes?this means that all of the structure is mutually supportive.if its a component that could be simply unbolted than it wouldn't generally count as part of the supporting structure but that's not the case on a ka.get a tape measure out and look,if the strut mount/seatbelt mount(normally the inertia reel mount in the boot) etc is within 30cm(or 12"in old money)which from memory it almost certainly is its a fail.as mentioned below the only acceptable repair is either a replacement panel or a fully seam welded patch repair.sorry,no nosh or filler allowed...

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 Posted: Tue Jan 19th, 2016 09:21 am
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goddens
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Mana: 
Does everyone consider that wing area to be structurally supportive of either the shock mount or seat belt mounting?

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 Posted: Sun Jan 17th, 2016 02:22 pm
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KevG
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The only acceptable means of repair would be a seam welded patch. Or of course a new rear 1/4 panel.

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 Posted: Sun Jan 17th, 2016 12:04 pm
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wakey1512
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Mana: 
Thanks chaps.

As for repair with it being so close to the fuel tank and the filler welding would be difficult without removing the fuel tank etc first.

The rear 1/4 panel affected is obviously not a bolt on part either.

Would a fibreglass repair be suitable?

Last edited on Sun Jan 17th, 2016 02:29 pm by wakey1512

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 Posted: Sun Jan 17th, 2016 10:27 am
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castrolrob
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as above,within a few prescribed areas,pretty much a death sentence,if its gone thru there then the flitch plates under the rear bumper are probably shagged too

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 Posted: Sat Jan 16th, 2016 11:20 pm
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Stealth
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Mana: 
Most likely it's within 30 cm of the upper seat belt mounting too.

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 Posted: Sat Jan 16th, 2016 08:14 pm
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KevG
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If its within the 30cm prescribed area yes, its part of the monocoque.
Tricky to repair too.



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 Posted: Sat Jan 16th, 2016 07:56 pm
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wakey1512
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2006 Ford Ka with the usual rot around the fuel cap. In places it has gone through. Fuel cap and filler is secure but corrosion is 30cm from a prescribed area (upper shocker mount)

Is it failable?

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