Rust repair, help a noob out!, Will keep updated with pics and info. Options

[Slick914]

This is going to be my first time trying to repair rust on a 914, so hoping to get lots of help and advise as I try to tackle this job. I'll keep this thread updated with photos and questions as I move along.

Here's the areas that I'm going to look into/repair. I realize the visible exterior rust is probably only the tip of the iceberg, so I'm preparing myself mentally for the worst. (IMG:style_emoticons/default/sad.gif)

This is the passenger side where the rear floor pan meets the rocker area. Someone thought they were doing good by putting a crappy spot welded patch over who knows what. (IMG:style_emoticons/default/mad.gif)

(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/rust003_700x525.jpg)



Here's the same area viewed from the back. Notice the rust extends around the donut as well.

(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/rust004_700x525.jpg)




The driver side looks better but there is one bad area with a hole. Similar location as the other side but the donut section is all good.

(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/rust006_700x525.jpg)
(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/rust007_700x525.jpg)




Current questions....

Are there reproduction panels that will replace these areas? I thought maybe floor pans would extend all the way to the rocker, but looking at the catalogs it seems they stop right in the middle where my rust is. (IMG:style_emoticons/default/sad.gif)

Am I going to have to custom make patch panels?

I see the donut triangle is available for that section.




I'm going to start by removing my interior and then the rocker covers. I'll then post more pics of what I find.

Thanks in advance to all who help me out along the way!

[Richard Casto]

Phil,

I agree with that Wes and Paul say. Before you start cutting stuff out, have an idea in advance how you are going to put it back together. I have seen where someone started to cut out the floor pan on a car but did it in such a way that they cut out a lot of good metal in places that they didn't. They then would need to go back and fabricate stuff that they didn't need to cut out.

As you already said, I would start by removing the outer rocker covers and interior to get an idea what is going on. There are a lot of options regarding replacement floor pans. As you noted the rear donut section is available. I think you are going to have to replace that. You are right that the floor doesn't go all the way to the edge of the longitudinal. It is welded to the inner longitudinal. The outer longitudinal is available as a replacement part. The inner is not. If the inner is rusted then you will need to fabricate something for that. My car was worse off in this area that your looks. Here is my page on my repairs...

http://motorsport.zyyz.com/project_914_03_04.htm

Other suggestions is that I would study other people's progress threads. It helps you understand how they have solved problems as well as gives you an inside view of the areas you are looking to repair.
I would also suggest that you get a good spot weld bit. I use a 3/8" Blair rotobroach and a center punch to create a dimple for it to center on when drilling. Use cutting oil to extend the life of the bit. I have been very happy with it.