2G Strut Tower Replacement

Posted by RevyDSM, Mar 13, 2017
Appearance/Interior/Exterior - All interior and exterior tech discussions; body and paint, conversions, lighting, washing, waxing, etc.

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  1. RevyDSM

    RevyDSM Probationary Member

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    Dayton, Ohio
    So I decided to tackle the #1 thing that NEEDS to be done before I do any extensive modding. The driver side strut tower is absolutely gone. You can press on any spot except around the strut bolts and it will flex. So I want to hear what you guys have to say and if you have any tips let me know. What's the best way to line the donor tower in the exact spot of the old one so the handling won't change?
     

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  2. mitsumikey

    mitsumikey Proven Member

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    Windsor, ON_Canada
    I feel like if your going to that trouble just buy a tower from miller import parts with no rust on it to begin with. Shop did my towers for me and it was a ton of work and measurement but they came out mint I can try and post pics later from home. Basically they popped out tons of spot welds and took out a ton of metal. lined the new one back up and welded away.
     
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  3. wishihadatalon

    wishihadatalon Proven Member

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    Grand Rapids, Michigan
    Mikey is right, you should probably find one without rust to begin with. With that said, if you want to patch the one you have, you're best off deconstructing the whole thing piece by piece, sand blasting, and replacing any rusted material. Deconstruction is a bit of a pain, but a good spot weld cutter will go a long way to getting it taken apart.

    The process I used on my tower replacement is as follows.
    1. Cut towers out of donor car
    2. remove seam sealer donor towers
    3. use spot weld cutter to get apart
    4. cut out bad rust on my car
    5. sand blast any and all residual rust
    6. coat all overlap seams and areas to be welded in SEM copper weld through primer
    7. line up spot welds from donor panels to original spot welds on car
    8. weld in new panels
    9. grind away excess weld metal
    10. epoxy primer bay
    11. use filler on any areas to be fixed
    12. profit

    Here is a public Facebook link to my tower replacement project pictures. It's not an easy job to do it right, but it is totally worth it to know that your car is structurally sound. https://www.facebook.com/tj.vangess...08102981531.1073741830.100000370576150&type=3
     
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  4. spyderdrifter

    spyderdrifter Supporting Member

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    Like the old saying goes, measure twice, cut once. But in the case of strut towers, measure 4 times, drink a beer, pray, measure again, then cut. :D
     
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  5. mitsumikey

    mitsumikey Proven Member

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    More cutback then shown. Custom made panel from back of strut tower to firewall on both sides. late but nonetheless here we go 1 2016 Spring (2).jpg 3.5 2016 Fall (0.5).jpeg 4.5 Winter 2016 Nikon.JPG 4 2016 Winter (9).jpg 3.5 2016 Fall (2).jpeg 4 2016 Winter (39).jpg 4.5 Winter 2016 Nikon (18).JPG 8 2016 Winter Nikon.JPG 4 2016 Winter (17).jpg 5 2016 Winter.jpg 4.25 2016 Winter.jpg
     
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