Project I Hate Rust: Phase 1

[Crazy_pilot]

So I've put a few of these pictures up in other places but figured I should throw them all together. Since my SVX blew a fuel line I've been stripping down the rear subframe to restore/rebuild everything. Phase 1 of this project will be to tackle the functional and mechanical stuff: Fuel lines, brake lines, de-rust and restore the chassis, subframe, control arms and brackets. I Hate Rust Phase 2 will be the exterior body restoration. Time for a photo-journey!

As always, for the big versions of these pictures go to my Photo Post.

Subframe down and tank removed:





And now for the de-rusting. I'm using a 5 gallon bucket containing a mix of water and sodium carbonate with a 12V, 5A power supply providing juice. Negative to the part, positive to the metal sheet lining the bucket, and a day or so of soak time strips all the rust, grease and most of the old paint off the part. Then a quick scrub with the wire wheel and a wash and it's paint time.



Before and after electrolysis:



And a before and after paint:



Today I got started on the chassis. My plan was to take the rust down with a wire wheel/grinder and then protect it with some POR-15. Seems like it might be a bit more work than that...

Upper frame rail. Not bad.



Forward frame rail. Bad. Big picture to make the gory details nice and clear.



So next step is to go pick up a switch for my welder and some steel so I can start patching things up.

[Sean486]

I think this thread is going to bring a lot of valuable information. I'm looking forward to seeing your progress.

[michael]

Last pic looks like your car is resting on four tiny tyres.

[Tapani]

I hate rust too !

Good luck - I will follow this thread closely.

Kind regards,

Tapani

[Crazy_pilot]

Got things cleaned up a bit more today. An interesting observation: under the relatively thin outer steel of the frame rail is a MUCH more substantial piece of metal that has almost no rust on it. Makes me feel more comfortable that my repair shouldn't undermine the structure of the car.

Going to apply the POR-15 to the areas that don't need repair tomorrow. Welding to start this week once I pick up my argon.

Side note: spot drill cutters are awesome.

[Crazy_pilot]

And now with POR-15 applied. Quite a process, this stuff. I'm also surprised by how much mileage you get out of it. I bought a pack of 6 4-oz cans and poured half of one into a cup expecting to use about that much on two coats. Turns out I overestimated by a factor of 5 or so. Brushes on very thin and smooths out really nicely. It's very sensitive to any oils on the metal though. There's so much undercoating on some parts of my car that it's continually seeping out, which is making the POR-15 have a hard time covering those spots. But if there's oil seeping out it should be pretty rust-resistant anyway.

['E']

I'm glad we don't have that issue here

[Crazy_pilot]

Working on getting my fuel system refurbished and back to new shape. I bought a full set of hard lines from the dealer and for extra protection ran a length of heat shrink tubing all the way down. I'll also be coating the exposed areas with POR-15 to make it a really bulletproof and long lasting installation.

[Sean486]

Overkill? ...maybe but it's still awesome. Nice job.

[gwynethh]

Plain heat shrink or the adhesive lined version?

[svxcess]

You can get by with regular heat-shrink along the length and just use a small piece of adhesive-lined tubing, overlapping the tubing at each end, to seal out moisture and air.

This is what I use a lot. It has a high-shrink ratio of 6:1. You can shrink it down over the wire and connectors for seamless protection. Great for slipping it over existing wiring without cutting or removing connectors.

http://www.cableorganizer.com/heat-s...si8aAgPl8P8HAQ

.

[Crazy_pilot]

This stuff is 3:1 self adhesive shrink tube so it should be pretty impervious to moisture intrusion. My biggest worry was that it would stress the hard lives and tweak some of the bends but that seems to have not been an issue.

[Crazy_pilot]

Took a bit of time yesterday and today to clean up and paint my rear diff:

[michael]

Très Bien. I really admire your attention to detail. Keep up the good work! I know what it's like to want something looking good/preserved, even if your the only one who may or may not ever see it

P.S. If your going this far you may want to invest in a product like Neverwet to keep that from happening again.

[theflystyle]

The work your doing looks great.

Are you going to replace the old bolts with shiny new ones