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| Rusted out upper frame rail repair suggestions (Page 1/2) |
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A_Lonely_Potato
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JAN 21, 02:09 PM
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Hey all, while pulling off my rear wheel well liners a bit ago, I was shocked to find my driver upper frame rail(and almost certainly passenger rail) is completely rusted out. This is something I really should have found when purchasing the car, but my nerves had the better of me with it being my first car. There were a lot of things i missed. Anyways, I plan to clean up whats left of the frame rail and fix it. I have a couple ideas for how to go about it, but would like to get the opinions of those much more experienced than I am.
This is how badly gone the rail is:
As you can see, the trunk is also starting to get pretty bad, but I wanted to keep the thread more focused.
My primary idea is to clean and square up what is left of the rail, and weld in a bracket somewhat like this:
(The blue cylinder is just a reference point of the strut tower)
Its just a rough example, but I feel it gets the point across. Of course I will be POR-15-ing everything I put in. If anyone has suggestions or better ideas I am all ears!
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RWDPLZ
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JAN 21, 02:22 PM
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Dennis LaGrua
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JAN 21, 05:48 PM
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Some kind soul posted this a while back and it provides the dimensions for making a new frame rail.
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" THE BLACK PARALYZER" -87GT 3800SC Series III engine, custom ZZP /Frozen Boost Intercooler setup, 3.4" Pulley, Northstar TB, LS1 MAF, 3" Spintech/Hedman Exhaust, P-log Manifold, Autolite 104's, MSD wires, Custom CAI, 4T65eHD w. custom axles, Champion Radiator, S10 Brake Booster, HP Tuners VCM Suite.
"THE COLUSSUS"
87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE "
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A_Lonely_Potato
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JAN 22, 11:34 AM
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Yikes! Really hoping I don't run into that much, but I suppose I should be planning for the worst.
| quote | Originally posted by Dennis LaGrua:
Some kind soul posted this a while back and it provides the dimensions for making a new frame rail. |
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Wonderful, I've saved the image in the event that there isn't enough material to salvage the remainder of the rail. Thanks!
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PhatMax
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JAN 22, 01:24 PM
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Here’s my mess… the one pic of the new metal is not finished , it did eventually get boxed in. 
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cam-a-lot
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JAN 22, 07:37 PM
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Not to be a party pooper... but are you sure it is worth the time and hassle? There are still a decent number of rust free Fieros lurking in the southern states. May be a lot easier to find another car than trying to fix up one that is so badly rotten. Your time has value too, remember that
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PhatMax
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JAN 23, 01:41 PM
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For me it was less time consuming to just fix it. The rest of the metal on the car is in great shape..
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Neils88
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JAN 23, 10:36 PM
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If you can weld and do metal work then doing a repair is the most cost effective way to go. There really isn't that much metal back there. It's also nice to see another Fiero saved. If you're not a competent welder (or don't have a friend who is competent welder) then you'd be safer just switching to solid southern Fiero. Of course, where I live it can be extremely hard to find a reasonably priced rust free Fiero, and so saving what you have is often the only choice.
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A_Lonely_Potato
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JAN 24, 01:35 PM
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| quote | Originally posted by cam-a-lot:
Not to be a party pooper... but are you sure it is worth the time and hassle? There are still a decent number of rust free Fieros lurking in the southern states. May be a lot easier to find another car than trying to fix up one that is so badly rotten. Your time has value too, remember that
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For the meantime I am. I'm lucky enough to be in a position that this project isn't hurting me, and I really would like to keep this car for a good while. Still got a lot of plans for it 
| quote | Originally posted by PhatMax:
For me it was less time consuming to just fix it. The rest of the metal on the car is in great shape..
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Unless I am vastly underassuming how long this will take, I can't imagine it taking that long really. I have the rest of michigan winter to get it welded all together, and that's just so I'm able to drive it in the spring/summer. If it takes longer than that, its not the end of the world
| quote | Originally posted by Neils88:
If you can weld and do metal work then doing a repair is the most cost effective way to go. There really isn't that much metal back there. It's also nice to see another Fiero saved. If you're not a competent welder (or don't have a friend who is competent welder) then you'd be safer just switching to solid southern Fiero. Of course, where I live it can be extremely hard to find a reasonably priced rust free Fiero, and so saving what you have is often the only choice.
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I'm confident enough in my welding that I trust myself for it. I've seen enough of my welds get bent and pass flawlessly while i'm finishing up my Welding Technology Certificate in school. If need be, I can make new frame rails with the specs Dennis shared. I would just prefer it doesn't come to that!
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reinhart
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JAN 25, 09:23 AM
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If you're getting certified in welding, then just look at this like practice.
The rust doesn't look *too* bad.
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