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Frame rail rusted through...worth a repair? Help!

31K views 16 replies 12 participants last post by  seb727  
#1 ·
Hey, guys. This seems to be a popular conversation these days, so I figured I'd toss my hat into the ring.

I picked up a '90 Hatchback for a project car cheap. It looked really good at first inspection, and the body was clean for the year. I started stripping the engine bay to pull the KA and prepare for the SR swap, and put the car on jackstands to pull the driveshaft and exhaust.

Well, I started to put it on jackstands, anyway.

One of the jackstands basically sunk totally through the frame rail on the drivers' side (where it bends up towards the shock tower behind the front wheel) as I was lowering the jack. Not cool. I jacked it back up, and cleaned up the underside of the car to explore a bit.

The front frame rail in that spot is rotten. There's a section at least 4 inches long spanning the entire width of the rail there that is just rusted through. The passenger's side doesn't appear to be bad. In the back, above the muffler, the frame rail is just destroyed, just behind the rear suspension. Rusted, splayed open like a flower blooming. There is various rust on the rocker panels, quarter panels, on the seam welds near the shock towers in the engine bay, and in the wheel wells in spots.

What's the opinion? The front portion of the frame rail and the rear part near the exhaust are my big worries. Without pictures, do you guys think this could be fixable? I'm nervous that the front is so far gone that it won't hold either way, and that the rear is so close to the suspension that it may permanantly affect that.

Any help/suggestions would be appreciated. Can I save it, or am I looking for a new chassis for my new SR20?

--->DJ
 
#4 ·
I figured as much. Here's an update as well, and I have a feeling that I know the response already...

My brother got on the creeper and rolled under the car so I could show him the problem. He got past the frame rail under the downpipe, looked up, and said, "Uh oh."

I was them able to stick a screwdriver up from the bottom of the frame rail through the 6" rust hole on the side of the rail next to the downpipe. Didn't see that one before. Basically, the frame rail right there is almost totally rusted through on two sides for a full span of six inches, and there is evidence that the outboard side of the rail is starting to rust through as well.

Is there any chance that it can be repaired, and that it will be worth the time and effort to have that done? I'd rather not start over...but I don't want a critically injured car.

Thanks for the replies.

--->DJ
 
#7 ·
Well im not sure about what im about to say even if its possible and cost effective but whatever. You could definelty do some crazy stuff, like replace both frame rails, and reinforce them at the same time.

The only way its worth the money is if all you have to do is pay for materials and you have the tools/time/interest/skill/patience. Its definetly over $1000 job getting it done at a shop, and to me, that exceeds the value of any S13.

Plus, you can obviously see someone has already tried to fix the problems with the rust and shock towers with the car. I would bet everything is totally out of alignment. Could very well be this car was doomed the second it rolled out of the factory.

Frame rails arn't exactly the easiest thing to replace, Im not even sure if a shop would really want to do it and a dealer would rape you until your inside out.
 
#8 ·
I was afraid of that. I picked it up for like 400 with a blown motor, so I can't really salvage anything from it. But i'm not out much either if I have to junk it and find a new chassis.

Question: I was thinking about having it towed to a local auto body shop to have them basically strip all the rust and do whatever is necessary for the frame rails. I'm not worried about paying a grand or so, but I don't have the welding tools or skill to do that part of it, so a shop may be the best option. I can do the swap and all the wiring and mechanical work, and the majority of the body work as well. Does anyone have an idea if something like that would be feasible?

Thanks again,

---->DJ
 
#9 ·
No fuck that, buy a new car.
You only payed $400 for it.
Im gonna slap you if you have it fixed.
S13s are dime a dozen, part it out.

Its just not worth it, wait a while and you will find a S13 with a wayyy better body for around the same price you paid for that one, just keep looking.
 
#11 ·
Why do you keep asking if you should have it "fixed"? A car with that much rust can not be salvaged. Sell it for parts or for scrap. Steel prices are very high right now. But trying to "fix" a car with that kind of rust is like trying to sweep clean a dirt floor - it will just keep falling apart.
 
#15 ·
Yup. This is old news. And for the record, one of my father's friends re-boxed the frame with new steel, primed, and painted it. Straight as an arrow, good as new...

...And then we came across a '92 coupe from Florida. No rust. We put the SR in that.

I advertised the repaired hatch for a while, but no takers on the shell (even at and below $400). We took the interior bits we needed, and sent it to the scrap yard about three years ago.

--->DJ