Solving MK2 Rusty Arches DIY Style

[Cupra Kid]

My MK2 is soon to be 11 so even though theres no rust showing on the visible parts of the arches i thought i'd try some prevention work. The problem with the MK2 arches is that they are a U shape trapping dirt in the middle of the U which then damages the paint and then once its set in start rusting through. Cleaning this area is very difficult as the arch liners block access.

So I took out the arch liners to assess the condition, they are easy to remove with a few plastic nuts and 4 screws. If they feel stuck its just the dirt trapping them in, give a good tug! This was the condition:

So all in all not too bad, but given some time it will creep round and become visible. I formulated a plan and hit the shops for some Anti Rust Hammerite in white and Karust rust treatment. I cleaned out the arches with a scrubbing brush and pressure washer removing all the huge amount dirt there, even picking at it in the hard places with my fingers! I then sanded down the effected areas and treated with Karust:

To gain the best access to the arches you need to remove the wheels and put the car on axle stands, on a side note my car with what was going to be its replacement if it had sold:

 

[Cupra Kid]

With the arches cleaned out i painted the inside of the lip and in the U shaped groove thoroughly with several coats of hammerite to get a good thick protective layer built up, I also decided while i was at it to protect the other exposed areas and welds in the arches with hammerite:

The paint takes 2 hours to become touch dry, i then refitted the arch liners after a good clean:

Final result with the wheel refitted:

No one would ever know

This should of now cured the rust and will prevent any new from appearing and creeping round onto the front of the arches. I painted inside the U shaped groove, the unseen inside edges of the groove and any other minimally protected areas under the arches including welds to the body.

The tools i used were:

Wire Brush
Sand paper
Cordless drill
Karust
Hammerite Metal Paint
Pressure Washer
Scrubbing Brush
Axle Stands
Hydraulic Jack
Socket Set
Screwdriver

As the hammerite comes in 3 colours only i would suggest black to other MK2 owners as this would suit the shadow of the arch the best, without drawing unnecesscary attention to the work.

The arch liners help to trap the dirt and hinder thorough cleaning, however i would put them back on afterwards as they hold the bumper in position and without them more damage may occur and aerodynamics may be affected.

A final suggestion would be to waxoil inside the arches.

Hopefully another 11 years should pass before this area needs attention once more

 

[AlpineWhite]

Good work Prevention is the best way. As you know, mine are too far gone!

 

[crezz]

unforuntly, once rust has started you will never stop it, just postpone it for a while...you need fresh metal if any...on the caddy there has been lots of new metal introduced! haha

 

[Fl@pper]

see the seam running vertical in this pic - always worth with the liner off giving that a 'good' tapping with a decent pick hammer as it's very thick sealer and hides the rot very very well

 

[CraigW]

Good work mate. Now I have an idea how to go about doing it.

Think I will stick with white hammerite as my car is white but then again black would work with the shadow as you say.

What did you use the drill for??

 

[jcs356]

I started with white hammerite but now just stick to red oxide anti-rust paint! It's not going to win any beauty pageants!

 

[Cupra Kid]

Good work mate. Now I have an idea how to go about doing it.

Think I will stick with white hammerite as my car is white but then again black would work with the shadow as you say.

What did you use the drill for??

Used the drill for flying the screws out in super fast time as some had siezed in, so WD40 and a decent screw driver bit got them out. Probably be just as good with a ratchet screwdriver or some real man power.

Also stuck a wire brush on the end to do inside the groove as my arms got tired

 

[jenk]

Every mk2 owner should pull out the inner arches and have a good clean, there must have been a few kgs worth of dirt in mine......and the odd bit of rust