In over my head - again.

[FrankT]

Need advice please -

Lots of rust in my 69T Coupe front suspension pan. Digging further, I discovered rust under L&R battery support longitudinals where the gas tank sits on the topside and the the front suspension cross-member bolts to the car on the underside.

front pan area

left suspension attachment point- from the top- note it's floating in rust

right suspension attachment point - from the top

right suspension attachment point - in the smugglers box


I bought a new "hump" replacement peice


Set front suspension cross-member on the new "hump" and the attachment point on the reproduction part is off by 1/8".




The large holes on the suspension cross-member should sit down onto the raised knob around the threaded hole on both sides- it doesn't.


Questions:
1. Should I attempt to replace the entire "hump" in one peice or just cut out the sections I need and keep as much of the original car intact as possible. Is there any strength advantages either way?

If I end up cutting up the "hump" to repalce only the rusty peices, the mis-alignment of the reproduction part won't be an issue. If I try to replace the "hump" in one peice then how do I address the mis-alignment?

2. Can I use the suspension cross-member as my jig (it has 4 attachments points) if I only replace one attachment point at a time - or is this a repair that should only be done on a correct frame bench.

Any help from those who have been here would be appreciated.

Thanks,

[efhughes3]

There is a FULL write-up on Rennlist of this replacement, step by step. Done in a garage.

[FrankT]

Originally Posted by efhughes3

There is a FULL write-up on Rennlist of this replacement, step by step. Done in a garage.

Is it in the Rennlist forums or a tech article? Do you recall what it was called or who posted it? Ive searched but cant find anything. Thanks.

[efhughes3]

In the 911 forum just last year. amj"something" was the poster. Quite a long running thread.

[b rock]

see if it's AMJF088 "Battery area suprise" Terrific post, great guy,very informative.

[FrankT]

Originally Posted by b rock

see if it's AMJF088 "Battery area suprise" Terrific post, great guy,very informative.

Yes, I found that one but it details replacement of the front-half of the suspension pan. I'm looking for the rear section of the pan "the hump" under the smugglers box and foot pedal area.

[b rock]

Why not take a shot and shoot him a message? He might have some ideas that may help you.

[efhughes3]

I think much of what he did would apply to you here. Dealing with spot welds, cutting, suspension pickup points, etc.