Skip to main content ↑ ↓
Topic: Rust repair (Read 4087 times) previous topic - next topic

Rust repair

I got situation here.

I have 87 Cougar with 3.8 V6 and AOD. I'm preparing to install V8 and AOD.
 Interior and body is in great condition. I've stripped the interior and found no rust inside or underneath the vehicle.

Only rust I found is on passenger side frame rail just above K member. [ see picture ]

I just hate to junk this Cougar.

What are my solution to that repair?
 

Rust repair

Reply #1 –
basically what you do is cut out the bad metal and make a repair panel the same size or a little bit beiiger so when you weld it i it is 10x stronger than before. also when your in there to make sure there is no rust in there at all cuz when rust starts its everywhere. I know from experiance. Hope that helps ya out also get some paint on the repair so rust doesn't ruin what you fixed. and def grind your welds smoot so it doesn't look like you did anything at all.
2001 Buick Regal LS (DD):hick:

Got that fox rash again!

-Resident smartass! :ies:

- Don't listen to the naysayers. For every person who actually helps with your project there will be 10 who will discourage you all the while thinking that they are helping. 99% of all people have good intentions. That doesn't make them right.- XR7 Dave - SCCOA.Com

Rust repair

Reply #2 –
 that sucks, i'm not sure of the exact size but maybe you could weld in some 3X3 tubing or something after cutting out the cancer
1980 birds X 3, 1982 bird, 1984 XR7, 1988 TC

Rust repair

Reply #3 –
your best (and safest) bet would be to rplace the entire frame rail as I will garauntee your bolts that hold the K member in a rotted too, like my '85 cougar was.  I am replacing the whole frame rail.  HUGE job though.  LOTS of spot welds to cut out.  plus lots of measurements needed to make sure the frame rail is put back in the same spot or you could REALLY screw up your car.

Rust repair

Reply #4 –
Quote from: 1WLD BRD;104225
your best (and safest) bet would be to rplace the entire frame rail .


Where can I get frame rail?
I'm assuming I have to find rust free frame rail from local junkyard.

What about Mustang frame rail? I've seen a lot of use Fox body Mustang in local junkyard.:dunno:


Quote
I will garauntee your bolts that hold the K member in a rotted too.


Yes, I'm expecting that.
:mad:

Rust repair

Reply #5 –
That is exactly why I junked my parts TC - the frame rail was rotted out on the driver's side. It was worse than yours, though - this one was actually broken (you could kneel on the front bumper and watch the fender flex).

Pics:

The car is upside down in this one, so the pic is looking "up" at it


And this one shows how it cracked right around the underside


If you don't replace the frame rail, at least remove the K-member and repair the whole thing, including where the K-member bolts on. In addition to the rust that 1wldbrd mentions, you can pretty much be assured that the underside of that channel is rotted right back around to the outside. You could have a sheet metal shop bend you up some fairly thick metal that would slide right over that section if the K-member was out of the way.

The good news is that unless you're building a show car, since it's in a hidden spot you don't have to make it particularly pretty.  That's the nice thing about floor and frame rust - you don't need to worry about body fill, glazing putty, etc. It has to be strong, but not shiny :D
2015 Mustang GT Premium - 5.0, 6-speed, Guard Green - too much awesome for one car

1988 5.0 Thunderbird :birdsmily: SOLD SEPT 11 2010: TC front clip/hood ♣ Body & paint completed Oct 2007 ♣ 3.55 TC rear end and front brakes ♣ TC interior ♣ CHE rear control arms (adjustable lowers) ♣ 2001 Bullitt springs ♣ Energy suspension poly busings ♣ Kenne Brown subframe connectors ♣ CWE engine mounts ♣ Thundercat sequential turn signals ♣ Explorer overhead console (temp/compass display) ♣ 2.25" off-road dual exhaust ♣ T-5 transmission swap completed Jan 2009 ♣

Rust repair

Reply #6 –
I junked my 88TC for the same reason. Thought the 87 was free of that stuff but I was decieved. It will meet the same fate one day. The next TC I buy I will be taking it completely apart to inspect it.

Good luck on your repairs. :)
2005 Subaru WRX STi|daily driver

Rust repair

Reply #7 –
After all the repairs are done, smear that entire area with POR-15. Used the stuff on the 77 Firebird I'm restoring and it's amazing. Take a sledge hammer to the stuff and it doesn't even ding. Plus it prevents rust.
<---One must always remember to Remain cool, calm and collected when dealing with your fellow man, especially on the Internet....
-DMC24guy
[/SIZE]

Rust repair

Reply #8 –
Quote from: DMC24guy;104291
After all the repairs are done, smear that entire area with POR-15. Used the stuff on the 77 Firebird I'm restoring and it's amazing. Take a sledge hammer to the stuff and it doesn't even ding. Plus it prevents rust.



I'm going to be painting my entire floors (inside and out) with that shiznit once they are done. the best part is you can paint over it too, giving a show quality look too.:cool:

Rust repair

Reply #9 –
POR 15 is good stuff.
Metal area must be free of grease, dirt and rusts before using POR15 otherwise the paint will flaked off.

I paint the firewall with POR15. My firewall is rust free but what the heck...paint it and get over with it.

Rust repair

Reply #10 –
Preferably you apply POR15 OVER rust so it will absorb it and prevent further rust, by applying it over a clean/smooth surface you can expect to have it peel at some point.

You get the frame rail repaired yet?
1980 birds X 3, 1982 bird, 1984 XR7, 1988 TC

Rust repair

Reply #11 –
Quote from: tbirdscott;107540
Preferably you apply POR15 OVER rust so it will absorb it and prevent further rust, by applying it over a clean/smooth surface you can expect to have it peel at some point.


My2¢..
Painting over rust isn't the smart way to do it. Best way is to removed all rust if possible then clean thoroughly, etched the metal surface then paint.
see picture below...it is from my truck...In 2004, I stripped the frame rail free of rusts, undercoating, grease and other chit. The paint still holds up.

Bottom line...
There is no perfect way to do it. Rust is like cancer. Rust never sleep and it spread easily regardless what kind of rust preventive paint is on the market today.

Quote
You get the frame rail repaired yet?


I'm half way done.
I'll post more picture of rust repair.

Rust repair

Reply #12 –
Just my 2cents but while the k is out change it to a better one it’s in my future plans if I ever have to pull my motor. It will give you nice header clearance and front end performance.

Rust repair

Reply #13 –
Quote from: Innes;107596
Just my 2cents but while the k is out change it to a better one it’s in my future plans if I ever have to pull my motor. It will give you nice header clearance and front end performance.


Thanks for your 2¢.
IMO...not worth to spent $$ on aftermarket K Member on daily driven car.

Rust repair

Reply #14 –
The thing is, POR 15 isnt paint.  Its designed to go right over the rust.  Of course, make sure its not flakey type rust to begin with.  Every body shop and supplier Ive talked to says the same  thing.  Clean it up a little to get the flakey  off, then put the por 15 on it.
88 TC, Lots of Mods.