Car has cancer!

[lanemeyer14]

Hey guys. Did some grinding on the festy today to see exactly what I'm dealing with as far as rust repair. Unfortunately it's worse than I thought. Here are some pics of the passenger side (drivers side isn't as bad). Can I just cut panels from a donor car and have them welded on? How far beyond the rust should I cut out? Should I try to cut where the seams are and just basically re-skin it? This is my first attempt at this so any input you guys have would be great!

[MONSOON]

You dont need to go more than an inch or so beyond where the rust ends. If you cut the panels from a donor car make sure you cut it large enough so youve got some to trim to fit it in place. And whether you weld it yourself or have someone else do it, make sure you/they take it slowly. Just spot weld it about an inch or so apart and as you weld it be careful that you dont let too much heat build up otherwise you have some warpage.

[lanemeyer14]

Yeah, I'm just worried I won't take enough out and I'll still have some rust hidden in there. I can look inside the hole and i see rust spreading down the rocker panel. If I try to get as much of that as I can with a wire brush and then put something on it like that por15 stuff, would that be good enough?

[wrestler3025]

I wouldn't go up that far lane. Do you see where you have the body line? I would try to seam the patch in there, that way you can blend it in. Take a look at my thread that I posted. It will give you an idea of what I'm talking about.

http://www.fordfestiva.com/forums/showthread.php?t=16340

If you have any more questions feel free to ask.
Joe

[V8Festiva]

I have a body that's wrecked with no rust. You are welcome to come cut whatever you need from it for free.

Dean
Raleigh, NC

[lanemeyer14]

Thanks Dean. As of right now you seem to be my only option for the replacement panels. If I'm able to make it to the meet next month do you think I could get the panels then?

[lanemeyer14]

I see what you're talking about wrestler....so i should cut it right below that body line? There is also some rust creeping in down the rocker panel (just on the inner surface). Should I just get as much of that out with a wire brush and coat it with something (rustoleum, bedliner)?

[ignitablepyro]

If there's rust starting on the inner rocker panel watch out, on mine it went a lot further than it looked and i know it'll be back to haunt me. If it's all bubbled up and nasty looking it probably started inside the body and came through. I would check the interior under the carpet at the edge of the floor panel if you think it might be bad enough. I found some all along the inside edge by the doors.

[lanemeyer14]

It doesn't look that bad to me. The outside isn't bubbled up at all, I can just see some rust color on the inside.

[V8Festiva]

Your welcome to get the patch panels at the meet. If you need any other parts let me know.

Dean
Raleigh, NC

[CharlieZ]

I'm working the same section. Got the right side ready to weld in and today I started the left side. Took two pieces since the donor car had rust in the rolled under/rocker area.

I need to figure out how to imbed images in the message. Somehow the instructions are beyond my grasp. <grin>

[lanemeyer14]

Sorry for being an idiot Charlie, but what are all the rod looking things attatched to the panel? Looks like you're doing a good job though! I only hope mine comes out looking as good.

[wrestler3025]

Hey charlie, looking good so far. Remember to take it slow when you're welding. Since our sheet metal is so thin, it can warp easily. That's why I opted to do the tiny tack welds, so it wouldn't build up a lot of heat and warp the panel. Good luck with it!

[CharlieZ]

Sorry for being an idiot Charlie, but what are all the rod looking things attatched to the panel? Looks like you're doing a good job though! I only hope mine comes out looking as good.

They are riveting clamps. We call them called Cleco Buttons. Cleco is a brand name. They are used extensively in the aircraft industry to hold and align panels while riveting. Couldn't live without 'em. Good close-up pix at: http://www.hansonrivet.com/w77a.htm

[WmWatt]

One way to do it is with pop rivets. You tap in the edge so it's recessed, drill and pop rivet the patch, then smooth the seam with polyester or epoxy resin, sand, and paint. Public libraries have books on auto body repair with photos, at least the public libraries in Cananda do.

I just undersprayed my car for rust prevention this winter and am posting a link in another thread in this forum.