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Old 11-30-2019, 08:20 PM
ernst ernst is offline
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Quote:
Originally Posted by ernst View Post
I am afraid I will have to do something about corrosion on the outside of my A4, see the attached images. I am afraid if I don't apply a coat of paint it will rust through at some point. I am impressed by what people on this list do with their A-4 antiques but at this point I am not going for beauty, just for utilitarian protection, i.e. rust prevention (or at least limit its progression). Here are my thoughts, please let me know if it makes sense.

First, I do not intend to remove the motor, I am planning to paint it in place. I realize this limits what I can do but I hope that I can get to the critical places to protect them from rust.

Then I have to decide what paint (system) to use. I know Moyers sells a spray paint which would look original but I given that the machine will be in place, I think that protecting everything from overspray will be much more work than brushing.

So I will have to select an alternative paint. I like the original look (which the motor has right now, at least on the small parts of it where there is still some paint left) and I found a brushable paint by Rustoleum which comes pretty close (can't find the link right now). But in the past I have made very good experiences with POR-15 https://www.por15.com (the regular paint, not the high-temperature version; I don't think the outside of an A4 ever gets hot enough for the latter to cure). It seems made for this application since it works best on rusty surfaces. They have a very limited color palette and nothing is close to the original Universal paint but, again, I am going for function not cosmetics. So it would most likely be a glossy black. I expect that the POR15 will not adhere to the few areas where there is still paint left so it will have a splotchy look but I am fine with that as long as the rust is kept in check.

So my plan at this point is as follows:

1) Remove alternator and top of distributor with all ignition cables, wrap the bottom of the distributor in a plastic bag for protection.

2) Wire-brush and vacuum all areas I can get to, using manual brushes of different sizes.

3) Protect surfaces around and under the motor with plastic drop cloths. Wrap the carburator.

4) Apply the POR-15 cleaning solution (Marine Clean) with a brush

5) Wash it off with water, either a fine spray (spray bottle) or brush

6) Put a thin layer of grease around each spark plug where it meets the threads as a lift agent, to avoid that POR-15 'welds' the plugs to the block

7) Apply 2 or 3 layers of POR-15

8) Crack a cold one!

One question I have whether I should remove the manifold which is by far the rustiest part. I am tending not to do it, afraid to open a can of worms. Does that make sense?

All opinions and suggestions welcome!
I lost my 'weather window' for this project. The boat is on the hard, the first snow (or ice pellets) is forecast, and I will likely not see temperatures over several days in the paint-compatible range until early spring.

So, when looking at the pictures again, I still wonder if I should remove the manifold. I know it is three bolts, plus two at the exhaust. My question is, how likely is it that I will break something in the process of removing it (like the studs), vs how likely is it that my paint job is not going to reach all the relevant parts and I will get a rust-perforated manifold some time down the line? I could start spraying PB-Blaster on the nuts pretty much now, and continue about bi-weekly (when I check on the boat) until March. Would that substantially increase the likelihood of getting the nuts off without breaking anything?

Any thoughts welcome!
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