I found rust !! (in my 73.5)

Deschodt · 04-01-2005, 05:59 PM

Surprise !!

Really, I sorta kinda knew about it, but it goes to show you how a bubble is just the tip of the iceberg. I was removing the rear panels to dye them black and install new seat belts, and the rear parcel shelf came out with a really soaked and stinky padding. Typical 911 rear window corner, been there before... (on a galvanized car however)

From the outside it looked like a weird place for a bubble, too far from the seal... Ha:

And here thru the lip but under the engine lid:

Makes perfect sense now that I see the inside, it's a bit soft and you can poke thru to the engine compartment in the corner, the rest is surface.

Good news? It's the only rust in the car and like I said not a complete surprise. Bad news ? I am not sure what to do about it. Part of me wants to dremel it, slap por 15 and drive the car a bit before committing to a fix and a paint job. But, now that I know it's there, it's gonna gnaw at me, and putting in the interior bits to eventually remove them again for a fix + paint is kinda silly...

How much do you think I should expect to pay for a repair there... In truth, I could not care less about the prettiness of a fix that is 2/3 hidden by the parcel shelf on one side and the engine firewall padding on another. It's just the outside bubble that needs to be prettied up, the rest can be crude and efficient welding...
Not too structural, right ? Ideas? Comments, BTDTs ? ;-)

Greg.

Deschodt · 04-01-2005, 07:28 PM

62 viewings and not one opinion ? You're killing me people... What, am I closer to $500 or $5000 ? ;-)

1973911s · 04-01-2005, 07:30 PM

I'll bite, $1500.

Michael

ianc · 04-01-2005, 07:36 PM

Hey Greg me lad,

Marco had a very similar problem on his brown 72. The rear window is going to have to come out of course. He was able to just shape a galvanized plate and rivet it into place after cutting out the rusty bits and treating the whole thing appropriately.

The part outside the parcel shelf is a bit more bother though what with paintwork and all. Knowing you, you'll probably have the whole car painted now to take care of it.

Couldn't really guess what it'll run you, but as always, the more you do yourself, the less it's going to cost...

BTW, what is that strange looking hose thingy by the engine lid bracket in the second pic? Isn't that the famous horsepower reduction mod fitted at the factory?

ianc

Deschodt · 04-02-2005, 05:17 AM

Yes, it is the Famous A/C hose, and guess what, it works 10x better than on an SC (more vents) - which is still pitiful, mind you - and is de-rigueur in Florida unless you wish to lose 1/2 your body water on the way to work !

As for painting you're not wrong, but I wanted to do that before anyway.... Just not yet, I wanted to drive the friggin' car for a while first ! The more I think about it, the more I think I'll just let it be for now. It probably took 10 years to get to that stage, I'll clean it up (screwdriver and wire brush), protect it and weigh my options. I'm not ready for losing the car for 3 months !

Question: If I por 15 the $#$% out of that area, will it make it more difficult to repair and repaint ? I think I read por 15 is difficut to remove ! (it is from my skin, anyway)

andrew15 · 04-02-2005, 06:20 AM

You could always cut it out and glue in a replacement or patch with some 3M panel adhesive..

Regards,
Andrew M

techweenie · techweenie's Garage

I agree with Michael. $1500.

That's if you cut out all affected areas and form steel patches to mate into the rear panel and the space between engine lid & rear window. You'll need an extremely talented welder to put the pieces in.

Seal 'er up, paint and put it back together with a new rear window seal.

If you can keep more than half the rear panel, you've caught it early.

Keep in mind that, typically, water that creates rust where you show it, pools on the rear seat bottoms and perforates them. Might as well get it all when you're at it.

cubby911T · cubby911T's Garage

Hey Greg,

While replacing the carpets/seats in my 70T this winter I found exactly the same thing you did. Both corners rusted clean thru to the engine compartment (see pics). Looks like about the extent of damage as mine - - limited to the corners. I decided to do what you are leaning toward.....
wirebrush, vacuum, and POR15 the $&^% out of it from both sides (interior & engine comp).

Like you said, aside from the bubble, it's covered up by the padding on both sides. I've already thrown $2500 at rust repair (front suspension pan) over the past year, and I just want to drive the car now.

Good luck!

Matt

Deschodt · 04-02-2005, 09:16 AM

Damn, your car look the same color as mine, that must attarct rust !

HEre are more shots, I cleaned it up, pulled the rear stuff and indeed found a swimming pool under the seat padding but thankfuly no rust there !

The whole area is maybe 2.5 inches wide, not all that huge !

My only concern is that por15 will make it worse eventually when I get around to fixing it !

Deschodt · 07:00 PM

Ok, last Q, I recall Por 15 sold some putty thingie that solidified real hard when mixed that I used in the past to plug a hole under the rear seat of my 356. How about I put some of that back there and sand it out? That should work, no? I'ts not a huge hole and I am not ready to paint it yet - I just want 3 months of driving until I do...