Rust Problem

[welfle18]

Alright well my rust problem is not an appearance issue, but I was wondering if anyone has had the problem I am having and what you did to solve it. There is a metal brace that the cross member and radiator brackets are connected to, well while I was installing my turbo its rusted so bad that one of the bottom brackets for the radiator mount rusted off. I believe from the looks of it that the other is not to far off. My question is what would stop the rust or is there a way to just refab that whole piece. Soon I am afraid I am not going to have bottom radiator mounts. Thanks.

 

[crimsondragon]

To stop rust, it is imperative to remove all the previous rust first using like steel wool or something similar. After that sealing it from the atmosphere is the next step. Paint is usually used.

 

[iluvmy4g63]

for stuff like this....i would get a wizz wheel with a wire tip... grind it to bear metal.. then get some good rustoleum.paint...( sorry if spelled wrong.) and just coat it down several times..its a way to atleast stop the rust...

 

[welfle18]

Well see that is the problem I think that it is beyond sanding or grinding. The metal is so flakey you can peel it away with your fingers. That is what sucks the most about it because that was my initial thought.

 

[Wicked_Sick]

Im not sure of the exact piece your talking about but is it removable? Any way to hit up the local junkyard in hopes of finding another?

 

[viperlp01]

That or just completely remove it and make a new custom piece and coat it with a truck bed liner. Im going to redo the hole underbelly of my car with truck bed liner. Im going to do all the wheel wells as well. IT is good stuff but first your underbelly will have to be completely clean...

 

[welfle18]

Well the part I am talking about is not removable well easily removable that is. It is spot welded to something (dont know the exact name of it) but I am sure you know what I am talking about. Its on the part the cross member is bolted to in the front and it helps support the radiator. It would almost have to have a custom piece made.

 

[welfle18]

Alright I found a picture about what I am talking about.

 

[1_2befast]

My 1g was all bent up from an accident in that area. I replaced it with some custom bent sheet metal and home made radiator brackets after cutting out the whole "crossmember." I would think that your best bet would be to get a cordless saws all and go get a donor piece from a junk yard. Then cut yours out and get the new one welded in place. It is a decent amount of work but that is really the only way to fix it if it is as far gone as you say.

Otherwise, brush off all the flaky stuff and coat it up with POR15. It is some amazing stuff. You should be able to find it easily with a google search.

 

[pullerfan]

yea there isn't really much you can to do save it now, its pretty much gone, and if i remember right thats part of your lower radiator support so unless you want to replace it, which wouldn't be a bad idea, your kinda screwed.. sry man.. you can alway custom fab something to hold the bottom of your radiator though..

 

[pullerfan]

That or just completely remove it and make a new custom piece and coat it with a truck bed liner. Im going to redo the hole underbelly of my car with truck bed liner. Im going to do all the wheel wells as well. IT is good stuff but first your underbelly will have to be completely clean...

yea i've also been thinking about doing this, i have to finish painting my car in class anyway so i figure why not protect it a lil bit too, this will help with sound deadening too which is always nice, let me know how yours turns out, pictures if you can

 

[Jeff99GS]

Oh its removable and you can buy that whole piece. It's called the Radiator Core Support. I replaced mine a few months ago.
The new core support I got from Ebay for 150. Here is some pics of before and after.

 

[98GSXtreme07]

Wow. Great post Jeff! And as for the OP I thought I had bad rust problems. I guess it always can be worst.

 

[Jeff99GS]

You will have to remove the Radiator and FMIC if you have one. Then you need to use and air hammer with a chisel bit to get the old core off. Using the chisel and air hammer to get between the layers of sheet metal and break apart the spot welds. Once the old Core is off you can use a grinder to remove any leftover bits of spot weld.

Now you will need to fit the new core on and WELD it in place. If you have a good spot welder that will work too. I mig welded mine while keeping the metal cool by blowing compressed air on the welded area in between welds. If you do NOT keep the metal cooler you will blow right through it with the weld.

Air hammer and Chisel bit

 

[welfle18]

Wow so they do make that whole support. Interesting because I thought that it was spot welded to something. Thank you very much and will look into that part further. Is it just bolted on or are there spot welds/welds to be broken. Just curious and overall how much work was involved? Thanks again.

 

[welfle18]

Thanks you beat me to it.

 

[welfle18]

I see your from Cleveland, I am from Norwalk. Boooooooo winter and salt for destroying the underbelly of our cars!

 

[welfle18]

Does that support connect to the 4 or 5 bolts that hold the bumper too?

 

[knochgoon24]

Wow, didn't know they even sold that support on it's own. Mine has some pretty bad rust there too. Not as bad as the OP, but still pretty bad. I used rust disolver, the rust primer, then a good outdoor rustoleum paint. Then I filled that whole member full of that expanding foam. I cut the excess off, added some bondo, sanded it off and painted it with primer and paint to match my car. Not perfect, but it's been 3 months and no paint from that area has flaked off. My hope was that if the rust can't get any more water, it should stop.

That replacement member might be on my summer project list now.

 

[Jeff99GS]

I see your from Cleveland, I am from Norwalk. Boooooooo winter and salt for destroying the underbelly of our cars!

Yeah the longs winters here and the rock salt kill them.

Does that support connect to the 4 or 5 bolts that hold the bumper too?

Yes there are two Pistons that go into the ends of the frame rails...those connect to the resin bumper piece. There are four 14mm head bolts and they slid right out.

If you want to buy the piece I can install it for you for a pirce. But it's A LOT of work.

eBay Motors: NEW RADIATOR CORE SUPPORT 95-9 MITSUBISHI ECLIPSE TURBO (item 250353336122 end time Jan-13-09 12:11:56 PST)

 

[Jeff99GS]

Wow. Great post Jeff! And as for the OP I thought I had bad rust problems. I guess it always can be worst.

Thanks man. Yes OHIO has one of the worst RUST problems for sure. I've seen 2 year old cars with rust haha.

 

[xioca]

Yeah the longs winters here and the rock salt kill them.

That's why the Midwest sucks.

 

[welfle18]

Well I am no stranger to body work. I worked for a company that built the International semi cabs. I have body work experience and well I guess that maybe the help would be nice but it wont be anytime in the near future because well I have a ton of other issues right now with the new turbo. But I am going to add you to my friend list and will keep in touch. Thanks again for the help.

 

[98GSXtreme07]

Thanks man. Yes OHIO has one of the worst RUST problems for sure. I've seen 2 year old cars with rust haha.

Yea, kind of sucks considering I live in Louisiana but my cars from Chicago. I've been told from a few shops, when they were working on my car, that if something breaks it's my responsibility to pay/fix what might break cause of all the rust on the suspension/underbody.

 

[Kastigir]

I see your from Cleveland, I am from Norwalk. Boooooooo winter and salt for destroying the underbelly of our cars!

Why I always wash my cars after the roads and they're liquid salt dry up. It's a good practice. Pay close attention to the undercarriage.