Rusty A-Arm. Usable or Replace?
 

I removed the entire front suspension from my '68 for a complete refresh, but after removing the bushings and torsion bar from the passenger A arm, I found a substantial amount of rust. The passenger torsion bar is pitted pretty good, so I will replace the front bars, but what do you guys think about the A arm? The splines in the end of the arm seem to be in great shape and the majority of the inside of torsion bar tube looks to be intact, but the last couple of inches inside seems quite pitted. There is also some pitting on the crossmember end of the arm that protrudes past the bushing. Being that the torsion bar floats inside the A arm tube, is this arm able to be cleaned up and used, or should it be replaced?http://forums.pelicanparts.com/uploa...1558147926.JPG
http://forums.pelicanparts.com/uploa...1558147926.JPG

Use a rust converter, sand it in a sanding box and reapply the phosphate (cataphoresis) treatment.
It will last 50 years!

Before reinstalling lube the inner part of the arm and the torsion bar with grease.
This will avoid water to attack metal again.

I would also insert wax into all of the cavities as these arms can rust from the inside out as well

That control arm probably is good for another fifty years. OTOH, a new replacement arm is only $265 and a used one, less than half that. Might be worth considering, depending on your goals for the car, peace of mind, or just plain fussiness! :-)

Throw it away. From the photos there looks to be some paper thin areas. Failure of the arm would make for a bad day.

Yup, toss it. They're relatively cheap. And fill the torsion bar cavity with enough grease to keep any water out and the new ones will outlive you and your kids.