Interior minor surface rust

[Wew]

Hi all,

New to the 914 world and taking on my first restoration. I purchased a runner all stock 1973 with fuel injection. The car does have some exterior rust issues as well as some interior as well.
I have cut out the rusted trunk portion and have a replacement piece ready to weld in.
The inside of the car has been stripped and there is some minor surface rust alonge with one spot in the rear drivers side corner I was able to jam a screw drive threw.
What the best way to repair these small rust holes and from a big picture perspective for a DIY amateur, what is the easiest way to remove rust other than media blasting?
I have attached a pic of the trunk and the interior that need to be done.
Thanks for your feedback.

Gary

[Dave at Pelican Parts]

The best way? Cut out all rusted metal back to solid metal, then weld in new panels. If we don't carry the panels you need, go to Restoration Design and get them.

Next-best would be to do the same, but fabricate your own patch panels instead of buying ones that are already pressed into shape. (This can actually be better if the holes you need to patch are small enough.)

Next is probably using a wire wheel to scrape off most of the rust, and something like phosphoric acid (Ospho, POR Metal Ready, naval jelly) on whatever is left, and then paint that. You're trusting (or hoping!) that there is enough solid metal left that the strength of the parts there is not too badly compromised.

Probably the worst way is to pop-rivet sheet-metal in place. Actually, come to think of it, fiberglassing over the bad panels is probably even worse.

--DD

[rkulina]

Another option, I looked at this metal spray repair process at the swap meet in Turloc. American Stripping Co. in Sacramento. They can spray weld a panel like that and repair the rust holes without panel replacement. Their number is 916-387-9934.

[Wew]

Thanks for the input. I cut out the section of the trunk already. Hell hole looks great. Don't know if somebody already repaired. The floor panels, I am not sure if someone put another panel on top of the old ones. I have included a picture of the underside of the car as well. There are a lot of little dents. Maybe spot welds. Input or thoughts on what these are and general impressions of what the underside of the car looks like are appreciated. I did measure front to back and diagonally from window frame to rear targa bar. Everything is even. I took off the little plastic rivets and removed the rocker panels. They look good. Some dirt and grit fell out but the rockers themselves look great.
The jack point housings had rust and I am in the process of cutting those out and welding on new ones.

[The Glademister]

Originally Posted by Wew

Thanks for the input. I cut out the section of the trunk already. Hell hole looks great. Don't know if somebody already repaired. The floor panels, I am not sure if someone put another panel on top of the old ones. I have included a picture of the underside of the car as well. There are a lot of little dents. Maybe spot welds. Input or thoughts on what these are and general impressions of what the underside of the car looks like are appreciated. I did measure front to back and diagonally from window frame to rear targa bar. Everything is even. I took off the little plastic rivets and removed the rocker panels. They look good. Some dirt and grit fell out but the rockers themselves look great.
The jack point housings had rust and I am in the process of cutting those out and welding on new ones.

The underside of the floor pans do look odd. Is there still under-coating there? The factory put a lot under the pans and in the wheel wheels. If that's been scraped off then someone may have already done some repairs. I would take a scraper and wire brush to those "dimples" and see what they are. Factory spot welds don't look like that. If anything, they're more like little round depressions. If someone did add donor floor pans on top of rusting original pans, well that's probably not going to be good. The two layers of metal will trap the moisture unless it was treated, painted and sealed really well. There also should have been a thick layer of sound deadening material on the floor pans. That stuff covers the pans and most of the tunnel in the interior. It also traps moisture and contributes to rust. If that material is missing then someone certainly has been repairing the pans.

If it's any help, my '73 914 (same color) was in much worse shape but I'm determined to make it live again!

[Wew]

you and me both brother!

[TheCabinetmaker]

Seen much worse. One tactic is to use a rust metal primer, put the carpet back in and keep it dry, the growth of the rust will be very slow if you fix the leaks that got it wet. If it got wet from a rusty fire wall (ie battery induced rust) then you need to seal up the leak in the fire wall. If it was from leaky roof seal, then get a new seal.

[ClausGraf]

Originally Posted by Dave at Pelican Parts

The best way? Cut out all rusted metal back to solid metal, then weld in new panels. If we don't carry the panels you need, go to Restoration Design and get them.

Next-best would be to do the same, but fabricate your own patch panels instead of buying ones that are already pressed into shape. (This can actually be better if the holes you need to patch are small enough.)

Next is probably using a wire wheel to scrape off most of the rust, and something like phosphoric acid (Ospho, POR Metal Ready, naval jelly) on whatever is left, and then paint that. You're trusting (or hoping!) that there is enough solid metal left that the strength of the parts there is not too badly compromised.

Probably the worst way is to pop-rivet sheet-metal in place. Actually, come to think of it, fiberglassing over the bad panels is probably even worse.

--DD

My 914 (1974 1.8) has the worst of both. Some panels have three layes of repairs. The first is fiberglass over the rusted sheetmetal (bottom of doors and fenders) then the next layers is riveted sheetmetal (FYI the car has a PA title) and to cover it all lots of bondo, up to 1/4 inch thick.

[ClausGraf]

[ClausGraf]