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!

[Slick914]

Got the interior out and rocker covers off. It doesn't look as bad as what I thought it was going to be. The rust seems to be limited to the same areas on both sides.

Here's what it looks like inside the car...

Passenger side looks to be all solid. The little surface rust you see on the floor by the inner rocker is just that, surface rust. I jabbed at all of it with a screwdriver and it's solid. Notice the patch on the upper firewall. I thought the lower firewall is the area that usually rusts? What do you think the deal was there? I don't think that is a main structural part of the car, and it's hidden so I'll probably leave it alone. It is metal spot welded on with seam sealer slapped on the edges.


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/interior001_700x525.jpg)




Driver side is about the same, all solid...


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/interior003_700x525.jpg)




Now onto the passenger side rocker/long area...


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs_700x525.jpg)




Outer rocker looks great and may have been replaced?


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs1_700x525.jpg)




Here's the bad spot. I noticed this area wasn't right so I ran the wire wheel over it.


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs5_700x525.jpg)




Guess someone thought they were making things better? This was covered with bondo. I can understand if you can't weld good, but why the hell would you go to the trouble to patch just some of a hole?


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs3_700x525.jpg)




The jack post and plate has been replaced, but I might have to remove it if it looks like there's some cancer under it.



(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs6_700x525.jpg)





On to the driver side, and again the outer rocker looks great.


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs8_700x525.jpg)




This side is pretty much exactly like the other side. Has the rust spot in the same exact place, but for some reason was left alone without any attempt of repair. Jack post/plate was repaired or replaced.


(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs9_700x525.jpg)
(IMG:http://i10.photobucket.com/albums/a125/philtheskipper/914%20repair/longs10_700x525.jpg)




Surprisingly everything above these areas, like by the suspension consoles, hell hole, battery tray, etc look very good. All is solid with no signs of rot. I'm thinking I might get away with just patching the bad areas I've shown so far. What do you guys think?


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