Fresh Air Intake under cowl rusted How to Fix

[1990new]

Festiva Trixie Fresh Air Inlet 2021-12 (4).JPG Festiva Trixie Fresh Air Inlet 2021-12 (2).JPG Festiva Trixie Fresh Air Inlet 2021-12 (6).JPG Festiva Trixie Fresh Air Inlet 2021-12 (3).JPG I'm sure this has happen to other people. My grandson's 89 had this happen and I need to know the best way to repiar.
There is a small spot that has rusted hole in the cowl at the back where this was spot welded on that I will need to fix also.

Can someone give me some advice about how to fix this? Festiva Fresh Air Intake (3).JPG

[1990new]

Duplicate photo removed.

[william]

Not sure if you could find one that hasn't rusted out but if you can in the junk yard id drill through the spot welds from inside the car and get the screen peace. Then clean up the inside of the Cowell as best you can with a wire wheel and wipe clean. Then sand the edge of the screen and glue it down with panel bold adhesive. I wouldn't worry about that small hole if the screen peace is solid. The adhesive will seal it up. If put a peace of tape over the rust so the adhesive wouldn't drip into the cabin.
If you can't find one im sure one could be made with some sheet metal and sscreen either way id glue it into place rather then welding unless you wanna gut the interior.

Now I need to go check and see if mine is rusty lol

[william]

Oh and after you repair id spray some corrosion protection inside the cowl such as sem or 3m cavity wax

[1990new]

Sounds like a good plan. Thank you very much William.

I will post some pictures of the repairs as I go along so this info will be here for future Festiva enthusiast.

Are these the two items that you mean?

• 3M Cavity Wax Plus, 08852, Self-Healing, Corrosion Protection, Non-Hardening/Chipping/Peeling/Cracking, 18 fl oz3M Cavity Wax Plus, 08852, Self-Healing, Corrosion Protection, Non-Hardening/Chipping/Peeling/Cracking, 18 fl oz
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• 3M All-Around Autobody Sealant, 08500, Medium-Bodied, Water-Based, Quick-Drying, 1/10 gal/10 fl oz Cartridge3M All-Around Autobody Sealant, 08500, Medium-Bodied, Water-Based, Quick-Drying, 1/10 gal/10 fl oz Cartridge
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$28.04

[WmWatt]

Rust paint before installing?

[1990new]

Rust paint before installing?

Definitely will paint with rust resistant paint as the finishing touch WmWatt.
I'm hoping the junkyard that has my old Festiva "Tootsie" has not had her crushed. The housing and screen should be good in her. I'll take my battery power sawzall with me it Tootsie is still there.

[william]

https://www.amazon.com/3M-08115-Panel-Bonding-Adhesive/dp/B000PEW4MI

This is what I was meaning only problem is you need the gun to dispense it. I didn't even think about that as I use the stuff everyday and have a couple guns manual and pneumatic. If you know anyone that works at a body shop they might be able to lone you a gun for the day. My local jober will loan them out.
If you weren't so faraway id loan you one. You won't need a full tube not even close so you may talk to a local body shop and get them to glue it on for you. It shouldn't be a big deal if you bring it in scuffed.

[1990new]

image_21627.jpg Did some wire wheel cleanup.to remove the rust. More holes showed up a the back as I removed the rust.
The sponge pieces you see are soaked in white vinegar. I will leave them there a few days to kill the rest of the rust before I paint the area with rust paint.. Festiva Trixie Fresh Air Inlet 2021-12 (14).JPG Festiva Trixie Fresh Air Inlet 2021-12 (12).JPG Festiva Trixie Fresh Air Inlet 2021-12 (8).JPG Festiva Trixie Fresh Air Inlet 2021-12 (11).JPG Festiva Trixie Fresh Air Inlet 2021-12 (10).JPG

[theastronaut]

That looks like a good area for Evaporust Gel. It looks like there is still some seam sealer around the opening, make sure to remove it to get at any rust that has crept under the sealer. Epoxy primer will be the best option to seal up the metal once all the rust is gone, you can get it in rattle cans that have an inner chamber with hardener for small jobs like that. Poor15 or similar products wont' stick if there's no rust so stay away from those.

[1990new]

That seam sealer is stuck to the metal almost like a steel weld. I used a big sharp flat screwdriver and hammer to remove some of the piece at the front but I can't really get to the area at the back the same way (looks like most of that at the back came off with the top hat part that had rusted thru anyway). There was no rust under the sealer in the front though. After two days of the ascetic acid (vinegar) soak and then scrubbing with backing soda tooth brush it look like I have killed the rust pretty good. I have ordered some more 1/8 shank wire brushes and will go back over everything really good to get it nice and shiny before I paint with the epoxy primer (thanks for the tip on that). Will post more photos later.

[1990new]

Sad news... Since scrap steel prices have almost doubled in the past two years around here it was inevitable I guess. Looks like Tootsie has fell victim to the shredder and is no longer with us.
I delayed too long in going out to get the fresh air intake cut out of her.

If anyone has access to a donor Festiva with a good fresh air intake, please let me know how much you would charge me for it shipped to me here in Charleston SC.