Rocker Rust Worries - opinions please!

phaques · 02-25-2003, 06:40 AM

After having just invested many hours and dollars upgrading the suspension on my 79 SC, I have found that on both sides of the car, the body area around the jack points has some deep rust. ON the driver's side, there is also a silver dollar size rust hole on the door sill just at the rear end of the rubber sill strip, right where (I think) the factory weld is. On the under side of the body directly below that, and just to the rear of the jack point, is lots of deep crunchy rust too.... Same story on the pass side, though the door sill seems fine - just the same rust situation to the rear of the jack point.

Took the car to a FLABS (Friendly Local Auto Body Shop?...), and the guy says he is not sure he can reinforce the driver's side jack point to where the jack point will be useable again! What does this mean for the strenght of the car at that point, particularly since I plan to use it about 90% for track use?!?

What would you do?
Find another body shop?
Fix?
look for another tub?

02-25-2003, 07:08 AM

Talk to someone who's into Porsches and has lots of experience.

Tim Walsh · Tim Walsh's Garage

that's a pretty typical spot for rust. If you're handy with a welder it's not a big deal. dtw and jamie (forgot his username) can help you out. THey're both pretty good with a welder.

k9handler · 02-25-2003, 07:15 AM

I paid a local guy $30 today and he welded up a piece of metal for me...all in all a good job. I have continued with my POR-15 coating to prevent further rust...good news was this one spot was all I found.

phaques · 02-25-2003, 07:27 AM

I'm paying a lot more than $30.... this guy sounds like he has seen this before, and is somewhat familiar with porsches.

anybody got any body shop recs in northern or central VA?

fax

jpnovak · 02-25-2003, 08:32 AM

The area you are refering to sounds like it needs more than a $30 fix. The jack tubes are supported by various layers of the structrual sheet metal. Lets see if you understand this description.

The jack tube is basically a square tube that is crimped on the one end (hidden from view). This end sits all the way on the far inner rocker on the interior right behind the rear of the outer seat rail. The upper part of the jack tube rests on the heater duct tube as it runs inside the longitudinal. There is a lower support which holds this in place. The inner rocker panel then covers the jack tube and the jack tube support is welded to the inner rocker. The outer rocker then covers this entire area. There is also the door latch post and quarter panel to deal with if you need to access this area, not to mention all the lead filler that is factory installed.

Typically rust can form when there is a breach in the lead filler on the inside rear fender well. This is not a good thing as the cancer spreads.

In order to repair this area at a minimum the outer rocker must be removed, or at least a window opened up to expose the jack tube and support. Once you get to this point, the decision has to be made to go deeper depending on how bad the damage is. If the jack tube support is rusted away look for more time and money to fix correctly.

If you don't feel to scared and have access to a welder its not difficult, just time consuming, to slice into the area.

The rust in the sill behind your door sill trim is not too uncommon. I have seen it on several cars. You can look at my website (link in signature) and see how I repaired it, along with replacing the rockers.

If you are going to track the car - get it fixed! The longitudinal area is very structural. If there is a hole, it makes it easy for water to run inside the rockers and start to rot out other areas.

If y ou have any more questions, PM or email myself or dtw on the board. We have both explored the inner workings of the structural 911.

Jamie

Tom F2 · 02-25-2003, 08:35 AM

I would not spend more money on this car. Just my point of view.

Tim Walsh · Tim Walsh's Garage

AHH I knew the welding god would chime in sometime

02-25-2003, 08:40 AM

Why would this area rust on a 79?

Jim Sims · 02-25-2003, 08:46 AM

Once the zinc is gone in an area the iron in the steel begins to rust; galvanization doesn't stop corrosion it just slows it down.

phaques · 02-25-2003, 08:55 AM

Jamie - thanks. You went pretty deep in your rocker project. Makes mine look like child's play. I'll be in touch.

Huey581 · Huey581's Garage

You mean like this?? Had this repaired and reinforced
for $ 350.00!!!!

I actually bought a doner piece from Stoddard that I had welded in.

phaques · 02-25-2003, 09:31 AM

Yeah, kinda like that, except big and round. and if you get down and look up from underneath the car, just behind the jack tube, same thing.
is stoddard a salvage parts shop?

Huey581 · Huey581's Garage

No. They are a Porsche dealer in Cleveland that stocks a whole
bunch of repro parts and panels!

k9handler · 02-25-2003, 11:16 AM

mine was not that large, and a small piece of metal was enough to patch it...once ground down and covered with POR-15 you would never know. I am sure if it was in a support area of the car I would have had to do more at a greater price...lucky I caught it early.