RUST

[commostud]

How much rust is too much rust. I have a 83 FJ60 with surface rust on the frame but, but both front doors have rust in the metal between the hinges. And I found some perforations on the roof and today I ground out several of them and used some body filler on it. The tail gate has the bottom of it rotted of and the lift gate is growing rust. (if I were to sandblast it, it might live alot longer. I also have a leak around the passenger side, when it rains it leaks onto my floorboards. I tore my dash apart and found rust underneath the window. I used some caulk to plug the hole but that did not fix the rust. The good thing is that the engine runs good (the mechanic of the PO said it was rebuilt) but idles high, with a new clutch. When I went a to look at it I crawled underneath did not see and body rust or problems so I paid her the 3400 smackers and drove her home 5 hours. But now I feel like a idiot and i will not even let the wife catch a whiff of that because I almost begged to get it. I love a good Looking FJ60.
My plans are to sand blast the frame in the auto hobby shop when I finish my PCS to Fort Gordon. I don't know what to do about the rain gutter area of the roof other than basicaly BONDO it and paint it but the other area I can weld sheet metal into the affected area. I am going to use durabak-18 for paint outside and durabak for the flooring inside.

How long does the body have left to live? And if anyone has some fairly cheap ideas Please let me know. Thank You

 

[RS41AB]

As much as you are willing to fight it.

The frame would be my main concern, along with any spots that are part of the main body like gutters or at the base of the windshield. Sounds like you should also check the round rear shock mount bar. Those are prone to rust at the frame joint. I speak from experience because mine recently cracked and completely broke off. You'll need a welder for sure, and some fab tools.

I have posted these before, but before and after , for inspiration.

 

[commostud]

I will check the rear shock mounts. I have to make some pictures smaller and I will post a couple. I want the welder and the tools, just takes time and money. Not easy to come by most of the time. I have the time to work on it, just money. Well that is most peoples problem. Thanks for the pics, and that does look nice! Jason

 

[Micah]

Sounds like your inside leak is coming from the a pillar.

mine does the same thing, it dose not rain much where I am so it is not that big of a deal for me. But I will get it fixed sometime.

 

[Wile E Coyote]

Ouch. The doors, and lift gate/hatch are a lesser problem to me, as even if they are waaay goners, they can be a color-matched paintjob and a couple bolts away from replacement. Your roof rust sounds fixable, but most worrysome is the rust behind your dash. Is it just the roof holes, or the a-pllar as mentioned? We shall see.
Post up some pics, and also search 'Mud. I've seen some moderate looking rust become a truck-killing monster once the owner got to digging deeper.


BTW, I was on Stewart while they transitioned from 24th to the 3rd ID. I had a hell of great time getting my Ramcharger stuck out on the swamped tank trails. I even drove a 93 Mustang out there many times for various job sites (assigned to 92nd Engineers) Also got a kick outta scarin my visiting family with the gators out on Pond 4.

 

[commostud]

Yup Pond 30 is off limits to everyone because of the 12 foot gators and over abundance of rattlesnakes out there. The MPs are even getting chased by the gators. It is a little funny. I took my kids gator looking couple of weeks ago and only say a small gator at holbrook pond. I am in 1bde 3id in 5-7 cav. The 92nd guys are always deployed. I am glad i am not in the unit. But I am under orders to go to Fort Gordon at the end of this month, with 30 days of leave to Montana. The Marne express has yet to stop running.

The rust is above the rain gutter on my roof on the passenger side. I found a bunch of pin holes and a couple of larger holes. I took my grinder to most of them and ground them out. Then filled them in with Napa body filler with fiberglass. The A-Piller on the passender side had rust too so I did that to. I ground off the sheet metal with the rust and underneath too. I took my time so I would not burn my headliner cause its in good shape. Then I filled it in with the same body filler. On the window the rust is mostly on the inside of the wagon with only a pin hole going to the outside. i will have to remove the window to get at the rest of it. I don't know how to remove the window without braking so I will have to wait for awhile before I can even get that fixed. I will have to find someone who will help me out on that on. Rust just makes me nervous because when I was in Kansas It was everywhere and cars just rot away while people drive them. I don't want that to happen to me. I paid way to much for this cruiser to do that. I want several years of driving from it.