Stress cracks

Discussion in 'Workshop Forum' started by PaulD, Mar 17, 2019 at 4:19 PM.

  1. PaulD

    PaulD Paul Davock

    Location:
    Kitchener, Ontario
    In repairing a rusted spot where the plastic plug goes through the door weather seal on the rocker panel, I noticed this stress crack:

    DSC_0438.jpg

    DSC_0437.jpg

    Is this a common stress crack area? My car is has 37,000 miles (confirmed on car fax), but there was evidence that car had seen at least one off road excursion. There were two bent wheels and flattening of the foot wells and tunnel cover. There are two small stress cracks at the top of the tunnel at the corners of the shift lever cut out. I drilled small holes at the end of each of these and left them. I wonder if there have been a lot of impact that has caused the cracks, or if it is a common outcome of normal usage? Should I check the the under body dimensions as shown on pages 70 -7/8 of the Bertone service manual?

    I will drill the ends of the cracks and have them welded (I only do gas welling, not the ticket for this). I will also weld in a patch for the rust area on the door sill. I was going to use lead with copper plate underneath, only if I am getting a welder in, I will do it right.
    another question I have is how do I rust protect the inside of the rocker panel after it is welded?

    Paul Davock
     
  2. kmead

    kmead Insufferable dum bass

    Location:
    Michigan
    It could be a bad weld as there are three panels (possibly four) coming together there
     
  3. Dan Sarandrea (Phila)

    Dan Sarandrea (Phila) Waitin' On Parts...

    Location:
    Philadelphia, PA
    Midwest-Bayless has a pic of the OEM replacement panel, that might help you decide a course of action:
    https://www.midwest-bayless.com/p-1...-frame-right-fiat-bertone-x19-all-oe-nos.aspx

    If you have the carpet out, there are some holes in the inside faces of the main rockers that allow some access into the interior of the rocker box sections. Also, if you take out the side scoops, there is a surprising amount of access into the box sections. A product along these lines might be what you are looking for:
     
    myronx19 and Hasbro like this.
  4. PaulD

    PaulD Paul Davock

    Location:
    Kitchener, Ontario
    It could be, I notice a gap in the weld. There is, however, a small crack on the other side in the same place.
     
  5. PaulD

    PaulD Paul Davock

    Location:
    Kitchener, Ontario
    The rust around the retaining plug is the only rust on the panel, I will likely hold off on a replacement.

    The 3M cavity wax is a great suggestion! Thank you.
     
  6. carl

    carl True Classic

    Location:
    Virginia
    I don't think cracks there are normal. However, the cracks up on the shifter tunnel are fairly normal, it seems every X I have had has them. I wonder what is causing the shifter area cracks?
     
  7. Dr.Jeff

    Dr.Jeff True Classic

    Location:
    Sin City
    Ask the Brit's about rust protection. They are experts and have lots of products and techniques we never heard of.
     
  8. mkmini

    mkmini True Classic

    Location:
    Latvia
    When mine was on rotisserie saw that it was flexing there. Welded these seems.
     
    PaulD and kmead like this.
  9. lookforjoe

    lookforjoe True Classic

    That's mainly 'cos most old British cars (even when new) leak so much oil, the undercarriage is protected :D
     
    7982X, kmead and AKimball92 like this.
  10. Dr.Jeff

    Dr.Jeff True Classic

    Location:
    Sin City
    If oil leaks worked to prevent rust, then none of our X's would have any rust either. :D
     
    Rodger likes this.
  11. mkmini

    mkmini True Classic

    Location:
    Latvia
    Can confirm:D that is what protected my Jaguar
     
    Dr.Jeff likes this.
  12. kmead

    kmead Insufferable dum bass

    Location:
    Michigan
    From the engine back...

    Wish that was true. My X leaks less than my Miata or Toyota Sienna. My 124 does have a transmission oil leak but its due to a stripped stud holding its steel pan on.
     
  13. carl

    carl True Classic

    Location:
    Virginia
    Well, if we were really smart, we would rig the crankcase breather to vent right next to known rust areas.
     
  14. Dr.Jeff

    Dr.Jeff True Classic

    Location:
    Sin City
    So basically that would be at the very front of the car where it can spray the entire body as you drive. :oops:
     
  15. carl

    carl True Classic

    Location:
    Virginia
    Could be! 124 spiders rust everywhere...except for the transmission tunnel.
     
  16. ghostdancing

    ghostdancing True Classic

    Location:
    italy
    it's the reason why i sprayed\brushed with oil\grease all the car..have to say the smell in the cabin is not that great, though
     

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