How To Repair Unibody Rust

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unibody frame rust repair

• Thread starter 79Cam->
• Start appointment Jul 25, 2006

• #1

i take a holes in the bottom and exterior side of my driver side rear frame information technology hasent spread upwardly into the body notwithstanding and i would like to keep information technology that way past cut out the rusted parts what gage canvass metal should i employ to patch the holes?

• #2

Most probable 18 guage is best. I promise you don't discover every bit big a surprise every bit I did when I started cutting my bad spots out.

• #3

I'd sandblast the framerail before cutting anything out. This will requite you a better idea of the overall condition. But my 2 cents.

• #four

only so i know what to wait for what a "big suprise" happen to be?

• #five

just so i know what to look for what a "big suprise" happen to be?

Big surprise is how much worse the rust is on the inside that what you can see now...wait below, what you see here afterward the outer frame rail is partially cut away. There is the rear portion of the inner torque box and to the left of that part of the rusty flooring pan is visible.

Click on my user name and you can visit my spider web site and encounter more detailed motion-picture show'due south of what I accept been going through. Also look in my photo gallery there are some more picture show'south in in that location too.

• #six

I've seen Steve's frame... The rust appears to be merely in the area closer to the wheel. I didn't see any sign of rust almost the floor boards, spring or shock mounts.

My thoughts on fixing information technology would be to cut the rusted bottom and side portions away so a made patch could be welded into place. I think he has the correct approach hither.

What gauge is the original steel for the rear frame rails?
I recollect it's heavier than 18 gauge.

• #7

What gauge is the original steel for the rear frame rails? I retrieve it's heavier than xviii gauge.

I put the mic on 18 gauge sheet metal tonight and it read 1.15mm or .048 inchs thick. I as well put the mic on a clean bare metallic frame rail and information technology read 1.15mm. On inchs information technology averaged about .053 measuring in several places it varied from .043 to .059. This is likely the result bone the frame runway have been pressed into form and probably have some stretching. 17 gauge is .055 inch and 16 gauge is .0625 inch or one/16 inch thick.

xvi guage sail metallic is getting to the point of not being hands worked into shapes with standard hand tools. Yes it can be done just it is not equally easy to work equally 18 guage. If the rust is slap-up I would probably just cut out the bad sections and make a box around the bad cut out area that covers farther out around the cutting out sections. If I were to do this I would try to use the 16 guage if possible for added force. If you are going to try and weld in a patch that volition not be noticable then I would go with the 18 guage....merely beware this is a stress area and I would be careful in doing the latter approach.

Try paging EliminatorSS as he sells some templates for making the cutouts to fix this trouble area.

• #eight

i already started today and similar terry said its non in to me floors yet i useing xvi judge cuz i thought 18 looked a picayune thin just im gonna weld in the patches and and so rap the frame with the same xvi then i will probly weld in some angle iron just to exist prophylactic...... i like to over build things similar i said in the bs topic though as i was welding in the offset patch my welder broke on me so i have wait to finish until i have the new slice

Last edited: Jul 27, 2006

• #9

ChevyReb... Cheers for measuring and checking this out!
Practiced info to have here for future reference.

I could have sworn the runway were 16 gauge! (I used to piece of work in metallic fabrication simply never actually measured the runway material.)

I agree with you on the methods and material choices for the repair options suggested.

Steve... Practiced Luck! Yous're on the right runway.

• #ten

79Cam->

Sounds good, but personally I would skip the angle iron. I don't think information technology will be nessasary if you lot wrap information technology, which is how I would do it as well. Postup some pics of the process for us to run across how you lot did information technology.

No problem Twisted...glad to do information technology.

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