I've tried zinc paints, less than impressive results.
Best paint on substance I've found so far is rustoleum rusty metal primer, in the brush on can. Cut it ~50/50 with acetone. So far, for me, it's been the top performer. Wears like iron, lasts for years outside, and when it fails is isolated and doesn't peel.
^^Good to hear. I used it (in rattle can) underneath the rustoleum on my "datsun" chassis.
Here is the major problem spot. There is one on the other side of the hatch too but not as bad.
For the record, the rattle can rustoleum products are completely different than the brush cans. And not for the better.
foxtrapper wrote: For the record, the rattle can rustoleum products are completely different than the brush cans. And not for the better.
Noted. 
Chemically different? Different thickness/durability?
Chemically different. Nowhere near as effective or as long lasting in the rattlecan.
Having said that, all this will probably change yet again, if it hasn't already (haven't bought a new can in a few years). VOC regulations may have forced a change in the formulations of either or both.
93EXCivic wrote:
On a Yugo I have to assume there will be nothing but the satisfction that it isn't rusty anymore as a byproduct of success so I'd lop off the lip with an angle grinder, clean with navel jelly, fill with Great Stuff foam, trim to fit. Paint if you must.
My assumption is you do not intend to put glass back in the hatch. Otherwise that's a fairly large and tricky section to try and build up with fiberglass.
Of course I'm planning on molding a full fiberglass hatch for my Yugo (wait, what? yes, I said my Yugo...details will be forthcoming) 
But overall I think everyone has you on the right path here. Without glass concerns this is just cosmetic and you should be able to lay some fiberglass over that and sand it out smooth.
In reply to JThw8:
I am going to put lexan in the back.
Do you need any parts for a Yugo? I have a whole extra car plus a bunch of other parts.
93EXCivic wrote: In reply to JThw8: I am going to put lexan in the back. Do you need any parts for a Yugo? I have a whole extra car plus a bunch of other parts.
You should be able to support lexan with what is left of that lip so no worries.
I don't believe I will need any parts, in fact I was going to see if you needed anything. Still got a bit of time until I pick up the car and parts stash so I won't know what I have but if you need something let me know, and if I run into any needs I will do the same :)
I should have a nice (well as nice as you can get for a Yugo) suspension setup with KYB-GR2 struts coming off the car since I have finally located the holy grail of Yugo bits, Konis!
I am basically completely ditching the rear suspension and I have X1/9 struts for the front. Are those GR2s for the Yugo or X1/9?
They are X1/9 :)
The rear suspension isn't such a bad setup stock as long as you lower it, preferably add a leaf to the transverse leaf and add a swaybar...actually you really need the swaybar no matter what. Addco still makes them but you probably wont find it in their catlog, might have to give them a call.
JThw8 wrote: The rear suspension isn't such a bad setup stock as long as you lower it, preferably add a leaf to the transverse leaf and add a swaybar...actually you really need the swaybar no matter what. Addco still makes them but you probably wont find it in their catlog, might have to give them a call.
I have something a little different planned. 
93EXCivic wrote:JThw8 wrote: The rear suspension isn't such a bad setup stock as long as you lower it, preferably add a leaf to the transverse leaf and add a swaybar...actually you really need the swaybar no matter what. Addco still makes them but you probably wont find it in their catlog, might have to give them a call.I have something a little different planned.
Coil over conversion no doubt :) It's easy enough to do, I considered it but I really don't see an advantage commensurate with the effort.
JThw8 wrote:93EXCivic wrote:Coil over conversion no doubt :) It's easy enough to do, I considered it but I really don't see an advantage commensurate with the effort.JThw8 wrote: The rear suspension isn't such a bad setup stock as long as you lower it, preferably add a leaf to the transverse leaf and add a swaybar...actually you really need the swaybar no matter what. Addco still makes them but you probably wont find it in their catlog, might have to give them a call.I have something a little different planned.
Easier to find shocks and run much higher spring rates.
93EXCivic wrote:JThw8 wrote:Easier to find shocks and run much higher spring rates.93EXCivic wrote:Coil over conversion no doubt :) It's easy enough to do, I considered it but I really don't see an advantage commensurate with the effort.JThw8 wrote: The rear suspension isn't such a bad setup stock as long as you lower it, preferably add a leaf to the transverse leaf and add a swaybar...actually you really need the swaybar no matter what. Addco still makes them but you probably wont find it in their catlog, might have to give them a call.I have something a little different planned.
Agreed, but the higher spring rate is accomplished by adding to the leaf pack, and I found Koni's for the rear too :) 7 years of hunting for a set and I find the fronts and rears (in separate places) within a week of each other and within a week of deciding to build a Yugo again...'twas fate. And they weren't even that expensive.
Giant Purple Snorklewacker wrote: ... I'd lop off the lip with an angle grinder, clean with navel jelly, fill with Great Stuff foam, trim to fit. Paint if you must.
Agreed. I'd cut the rust out, put some sort of primer on it, Great Stuff it, cut the excess foam, and skim coat with bondo. Worked for my BABE rally car!
93EXCIVIC,
Where do you live? Anywhere near South Coastal Massachusetts?
I can have that body work all buttoned up for you in an hour.
TC
I am in Huntsville AL.
thats loks like a sheetmetal repair to me. some 22g, grinder, snips, hammers and a couple blocks of wood will give you a great fix. its actually not that complicated for sheetmetal. its straight, got simple bends, and its gonna get glass over it.
there is too much gravity fighting you if you go with fiberglass. however if you used it somewhere else on the car. find some fiberglass 'tape' you can get it 2" 4" 6" wide. its got real nice woven edge, it is SO much easier to deal with that cutting pieces out of cloth or matt
watch the pull a part for a yugo and go slice that section out with a 18v sawsall or for that matter just go spend 30 minutes looking at other cars, i bet you find a section from who knows what.
BOOM. problem solved
"I am in Huntsville AL."
Oh, too bad. I'm in New England. That kind of repair is common in the rust and snow belt up here and pretty easy to fix with a bit of metal and some fiberglass.
We have a yearly safety inspection and rust through is a part of it. Everyone around here gets pretty good with fiberglass pretty quickly.
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