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What does rust repair usually cost?

I know this is a VERY open ended question...
I've gone meticulously through some great rust repair threads, but none of them actually talk about the cost (whether done personally or out-sourced).

I have typical rocker panel rust and probably even the kidney bowl as well... rust around areas of the oil lines in and rust at the corners of the front and rear fenders. There is also some minor surface rust around the contact points of engine deck lid.

So given the cost of the sheet metal, and the time it would take to do the metal work ($50.hr)... what would the range of costs?

So... for those of you who have repaired the common rust spots... how many hours would a professional welder require?

Keep in mind I'm only looking for costs to remove the rust and replace with clean sheetmetal, then treated and protected but NOT painted to match. (I plan on having a complete repaint some time later down the road)

What are your experiences in cost for our cars to have rust repaired?

FYI.. I've thought about doing the rust repair myself, but I am an OCD perfectionist who would spend WAY too much time trying to get it done perfect and therefore would never get it done.

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Old 12-04-2016, 09:39 AM
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Figure 8 hours per job minimum at 65 or so an jour plus replacement part cost.
Old 12-04-2016, 09:47 AM
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Quality and cost per hour will vary widely. Then once it gets started you are likely to find much more than you originally figured on.

I just spoke with a guy who is having his '71 de-rusted at a reputable So Cal shop.

He told me that the repairs are going to cost $30K MORE than the original estimate.
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Old 12-04-2016, 09:57 AM
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Originally Posted by Trackrash View Post
Quality and cost per hour will vary widely. Then once it gets started you are likely to find much more than you originally figured on.

I just spoke with a guy who is having his '71 de-rusted at a reputable So Cal shop.

He told me that the repairs are going to cost $30K MORE than the original estimate.
Wow... that must include a repaint and a complete frame repair, or it was in REALLY bad shape to begin with and having to buy a donor car.

I've been calling around and found about $50/hr... and given that I don't plan on a repaint (just an epoxy primer and whatever else on top of it to protect it)... figuring about 40 hours of work for both sides. Double that amount.. and add in costs for buying panels... I'd expect somewhere between $2500 if no additional serious rust is found - $7500 if the rust is more than expected.
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Old 12-04-2016, 10:51 AM
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Having done a few of these type projects...

It takes way more time than you expect to cut and replace panels and fix whatever other stuff you find while cutting it out. These projects easily snowball.
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Old 12-04-2016, 11:30 AM
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There's just too many variables to give a reasonable answer.
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Old 12-04-2016, 11:44 AM
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Quote:
Originally Posted by Trakrat View Post
Wow... that must include a repaint and a complete frame repair, or it was in REALLY bad shape to begin with and having to buy a donor car.

I've been calling around and found about $50/hr... and given that I don't plan on a repaint (just an epoxy primer and whatever else on top of it to protect it)... figuring about 40 hours of work for both sides. Double that amount.. and add in costs for buying panels... I'd expect somewhere between $2500 if no additional serious rust is found - $7500 if the rust is more than expected.
I did not get any details, and that was probably all the body work and paint.

If you can get all the rust repaired properly for under $10k that is great.

I de-rusted my car many years ago and it was not that bad, but still it is a lot of work. You will not know the extent of your rust until you strip the car down to the bare shell.

It will be interesting to hear numbers from those who paid to have it done.
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Old 12-04-2016, 11:47 AM
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Impossible to answer accurately. Unless we see the car and the rust, it's pure speculation.

$50 an hour? You must live in east jabib. That's dirt cheap.

FWIW I just had a very rusty BMW fixed and painted, with a total color change. I delivered the car totally stripped and I supplied the big sheet metal. (front fenders and both floor pans. He fabbed up the rest of the steel.)

I'm all in at about $8K, and I live in metro NYC. Porsches demand more $$$ because they're Porsches. Good luck.
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Old 12-04-2016, 12:02 PM
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Mine was $25,000 to be done correctly
Old 12-04-2016, 03:20 PM
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Mine was $25,000 to be done correctly
May I ask where your rust was found at?
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Old 12-05-2016, 07:38 AM
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Trakrat - seen several of your posts here and on the paint/bodywork forum. Just wanted to add a couple of comments. There are some amazing builds here and some amazing talent. I am a total slacker when it comes to bringing my car back from a track car to street car - partially because I don't have a lot of time, but also because I have found I really do not enjoy the process. My previous 911 was a 72 E rusty POS - I had a grand vision to restore it by myself - and then reality set in. If you do a crap job on the diy resto, it will show. Better not to try.

Anyway, I ended up selling the 72 because I was way over my head and I was pissed off every day I looked at the car. There are guys here that are gurus, and they make it look easy to mere mortals - these guys have major talent. Looking at the pictures of the progress can make it seem straight forward, but the process can be a whole lot more daunting. In the end it was a relief to sell to someone who was good at it. I have visitation rights.

After that I ended up with a Cayman, which was both amazing and boring at the same time. PDK is a marvel, but ****e too - if that is possible. Sold that. Wanted aircooled manual.

Bought the 89, rust free, just need to replace the interior, remove the cage, fire system, yada yada. Should be easy, but as it turns out, I am still not a diy guy.

Fortunately I am learning all of this on cars rising in value, so I am not getting (too badly) burned on price.

I expect some guys here just pay to have someone else restore their cars. No shame in that - My next 911 will be done the way I want when I buy it.

My long-winded point is - if you are not happy with the car and all it needs - and you don't want to deal with it (rust repair) just sell it on, and get another. You may lose money, which is never fun - but maybe it is time to move on?
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Old 12-06-2016, 03:20 PM
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I had the rocker repaired on one side of my '87 and some surface rust done on the other...then, the roof, quarter and both jambs were shot for $2300 in Michigan.
Old 12-06-2016, 03:26 PM
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there's just too many variables to give a reasonable answer.
^ this
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Old 12-06-2016, 04:55 PM
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It's going to vary depending on how the shop intends to do the work. I had rust on both my rocker panels and the kidney bowls done last year. One shop quoted me about $5000.00 to fix the rust and paint the doors and part of the rear fenders. Another shop quoted $15,000.00 but he wanted to replace both rear fenders, fix the rust, and paint the affected areas.
I went with the shop that gave me a quote of $5000.00. But then I decided to have a fiberglass rear bumper installed and a complete re-spray done. So I ended up spending more.
Old 12-06-2016, 05:44 PM
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I charge Pelican members $50 per hour plus expenses
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Old 12-06-2016, 06:40 PM
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Quote:
Originally Posted by Trackrash View Post
Quality and cost per hour will vary widely. Then once it gets started you are likely to find much more than you originally figured on.

I just spoke with a guy who is having his '71 de-rusted at a reputable So Cal shop.

He told me that the repairs are going to cost $30K MORE than the original estimate.
I understand hidden rust and the "unforseen" but a 30k misquote sounds fishy. Or the game plan of work was changed from the original estimate.
Old 12-06-2016, 06:51 PM
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As many others have mentioned rust repair is a slippery slope. Not my 911 but with my 240Z, we budgeted $15,000 to strip, weld and spray but since those things were literally slapped together originally, I stopped counting past $30k...and I stripped and assembled the interior myself. The result is pretty sweet, but it doesn't see much road time. Anyway make sure you have an idea where you want to land at and work backwards or things will get way beyond sensible fast.
Old 12-06-2016, 08:21 PM
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I charge Pelican members $50 per hour plus expenses
Honestly, I'd send the car to this guy. He has mad skills.
Old 12-07-2016, 01:11 AM
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Honestly, I'd send the car to this guy. He has mad skills.
Just don't let him drive your car - he likes to do those quick 180 turns using the hand brake!
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Old 12-07-2016, 05:30 AM
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Wow - Talk about open ended.

I haven't seen a restoration shop charge $50/hour in decades.

I think a Porsche rust project starts at $10,000 and can easily reach $50,000

My last rust repair was around $10,000 by the time I left the shop. The good part was most of the rust was in the seat pans so no color had to be sprayed. The rear shelf was also a big deal.






Keep in mind that all Porsche 911 projects seem to start at $1,000 and go up rapidly.

Richard Newton
The 1973 Rust Project

Old 12-07-2016, 05:44 AM
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