Iron Oxide, AKA RUST!!!

[firemansam]

ok got a question about rust and frame rails... I have a little rust problem on my passenger front frame rail. I thought it was just on the outter were the bumper brackets mount when my welded nuts came off during disassembly... I purchased an outter frame rail patch to fix it and finally got around to doing this and found some rather disturbing stuff... (pictures below) i realized the bottom of the frame rail was also suffering from the cancer as well as the very front of the inside portion. my big problem is the amount of rust scales and flakes that came off along the inside of the rail behind my cut. I went back a decent bit from the visible rust on the outside but this is what i found... do i need to replace the whole thing or open it up further back the same way i did at the front and clean it out epoxy prime it? thanks for your help in advance!

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[Fibersport]

Consider this, if you've lost 50% of the original metal thickness to rust, what percentage of strength do you think you've lost as well?

I've just brought my car home after storing it for 25 years, I've come to realize that I'll have to replace basically the entire car, I share your pain.

 

[Fstbk]

I think I would start with a frame fixture and build up from there...I had a 67 fastback that I sold in 1989 and the frames in front of the shock towers were so bad the bumper would not mount because the nuts were gone, upon further investigation I found rust nearly as bad as yours. Back then it was a death sentence for a car owned by 19 year old with no garage, but now I think I could fix it....with a jig (and the internet).

 

[firemansam]

so just bite the bullet and replace that whole frame rail then?

 

[Hack]

so just bite the bullet and replace that whole frame rail then?

Yes I think so. The replacement sheet metal isn't that expensive-it's just the time to do the work. You should probably have a really close look at the other side. It's probably not far behind.

 

[65fastbackresto]

Look at Rustys thread "65 Mustang Rust Repair"

It will give you very good ideas on what order to fix these things.

 

[firemansam]

thanks for the help guys. I wish there was a way to determine how much rust is on the inside of the frame rail since the outside doesnt look bad but it is pretty eaten up on the inside on this one. i have a little rust on the floor pans that needs to be addressed as well as a few small patches on the doors and quarters and b post area... guess i need to get to stripping and cutting out and burning in the new...

 

[firemansam]

so i have decided a couple things about this situation:

first i am going to replace the frame rail a the least if not both depending on need.

second i want to media blast the rest of the car

so this brings some questions to mind,

in putting the car on a dolley/ frame rotissery type contraption to do the blasting on where should i attach it to the car so i wont have to remove it and all when it comes time to replace the frame rail and other rusty spots?

i am looking at different media types, plastic, walnut shell, and a number of other options, what is best for the buck and what grit is prefered for this particular application? suppliers? any other help you might can offer in this, since this will be a lot of engine bay under side, and interior so chemical strippers arent gonna be too much help.

 

[other_shoe]

Back then it was a death sentence for a car owned by 19 year old with no garage, but now I think I could fix it....with a jig (and the internet).

I hear you. If I'd had the online resources that are available now back in the early '90s, I would have taken much different and better approaches to my car.

 

[firemansam]

is it safe to weld to the rocker panel area to set it up on the dolley? one at each end on each side? is that area strong enough without rust to support a shell to allow blasting and rust repair?

 

[firemansam]

well i finished teardown and found the whole floors need replacing along with that right frame rail... so i ordered and everything has arrived!! soon i will tear into it and get to cutting and replacing... any suggestions for bracing for all this removal and ideas for the best way to get that frame rail out and new one in? thanks for any help yall can give! i will be puttin some pictures up in the next couple days