Oh oh, found another rust problem: Pics
 

When notching the tub for my front oil cooler I came across some more rust. I have a few questions for those who have done this or know body work. Since the rust isn't in a major structural location I was wondering how to repair this. Can I just take it down to the metal, remove rusted out parts and fiberglass in where the hole is? Should I cut the piece from the car and graft in another piece from a dismantlers? Finally, what about repairing with a piece of sheet metal stock and crudely hammering it into shape?

Also, since I'm putting on F-Glass bumpers, I won't be using the bumper shocks or mounts, can I drill the spot welds on these and remove them making my rust repair job easier and shedding a little (albite not much) weight from an outter corner of the car? Or are these minor/major structural pieces?

Here are the pics of the dammage, not for the faint of heard :(

http://forums.pelicanparts.com/uploa...1074845637.jpg http://forums.pelicanparts.com/uploa...1074845647.jpg

Oh yeah, I'm not concerned about the brackets that hold the washer tank and the horn because I'm relocating both, not sure where yet but I'll figure it out :)

Adam

I thought the brackets were structural? I started removing the one on the drivers side after I pulled out the windshield wiper fluid tanks and after looking at it for a while I decided it wasn't a great idea. But I have no clue other that my opinion. AND.... your car has NO rust! SC's do not rust!
That is a dirt collection spot. Both corners with tanks hold a lot of dirt. Thats why I pulled the useless bottles. Nobody really knows whats lurking until the car looks the way yours looks now, apart.
I've decided to leave the oil tank even though it is a dirt collector.

It looks like the battery had leaked out there. If I were doing it, I think I would leave the brace but cut out the rot, and mig in some fresh steel there.

Isn't that bumper shock area one of the stupidest designs Porsche could have come up with? If I were you I would cut out the rusted area and form some sheet metal and butt weld it in. If you want to delete the reinforsement go ahead. I pesonally wouldn't. I would weld a top on the reinforsement after I fixed the rust

I just replaced the front suspension pan because of battery acid related rust. The area in the picture is a little high for that kind of rust, but I would take a look at the front suspension mounting point on that side as well as the area under the battry tray. That doen't look like dirt accumulated rust.

You can cut out the rusted area and weld in a doner piece or even make one yourself. Just what a video of Jesse James making a gas tank on TV and start banging away. You can get it perfect I did!

In my humble opinion as an Architect the bumper shock suport does add to the structure in that area, I wouldn't remove it"

Thanks for your help fellas,

The rust appears to have started on the outside of the car as the inner pannels are in great shape. Since i'm moving my battery anyways, I think I'm going to cut out the tray and take a peek underneath just in case, it looks clean but you never really know.

Still undecided on how I'm going to repair that hole in the above pics though. I suppose I'll need to wire wheel it all down and see how far the problem goes.

Keep the suggestions comming!

Adam

That is a common rust area, dirt collects on top of the bumper shock mount and it stays wet.

I'd cut it out and weld. If you really want it right, get a section. Else do your best forming sheet metal.

The bumper mount is not structural, except to hold the bumper. Early cars didn't have anything there.

The other area is the fender mounting seem. Doesn't look too bad, you can probably clean that up and treat with POR 15.

I think I'm going to drill out those spot welds and do the repair and leave the mount brackets off and see how it looks.

Thanks Chuck!

Adam

Adam,
Any update on the repair? These pics always give me that sick feeling so it's good to see progress.

Adam - Your signature says "1978 911SC 3.0 (former)". Is this car with the rust an SC or was an SC your "former" car?

How much stuff do you need to remove to clean above the bumper shock mount?

If you just want to clean the built up dirt out of there you have to take out the washer res.

Another question.

Is that rust repairable without removing the mount? Looking at the pic it seems the rust may go below the mount's (vertical) flat surface. I guess you could weld the new metal in from the other side if this is the case??