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]

The interior actually looks pretty good and the exterior not too bad at all. But someone has obviously done some repair work on the exterior on both sides. From the photos, the repairs don't look too bad, but not perfect. The triangle threshold supports are missing (love the wire loops on the driver side. (IMG:style_emoticons/default/biggrin.gif) ). The seam sealer also looks to be slathered on pretty thick as well, so it's hard to see what is going on behind it. Were they just putting it on thick or trying to hide/cover something? As you show, they either didn't fix some stuff, or didn't do as good of a job as the could in the places they fixed.

If it was me, I would strip the paint off both exterior longitudinals (everything behind the covers) down to bare metal. Then you can tell how much is real metal vs. thick seam sealer, bondo, etc. I would redo the patch you see on the passengerside (probably not hard to do) and fix the same area on the drivers side. I would try to obtain replacement triangle supports for the threshold on both sides. I don't know if you can get those on their own, but I know you can buy the entire threshold and supports for about $50 each side.

When done, you can seal it all up really nicely and either try to color match to the car, or paint it black since most of this is going to be covered by the covers anyhow.

Richard