2G Strut tower rust [Merged]

[95eclipser]

Iv tried reading a couple times but didn't see it. What size metal are people using to repair the strut towers?

16G?
or
18G?

 

[wishihadatalon]

The stock sheet metal measures in at .033-.035" which really puts you in the 20GA range. If I had to do it again, I would do 18GA though all of my issues have been on the stock sheet metal and not the replacement steel.

 

[95eclipser]

Thanks,

I grabbed some 18G today and a couple new cut off wheels

 

[jjw205]

I used 16ga but it was a little overkill and hard to form. But obviously stronger. But if I did it again, I would probably use 18. 20ga just seems too thin, even though its probably closest to stock metal.

 

[97_Talon_Esi]

This was my solution to the rusty strut tower problem. Grinder to the rust to clean the surface, 2mm steel scrap metal from work. Cut the sheet metal and welded it together. Painted it with ceramic engine paint from a rattle can.

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[95eclipser]

I ended up ordering an entire strut tower from Miller Import Parts. My Strut was completely rusted through and the shop wanted one from a clean parts car.

 

[Black95TSIawd]

Brave gentlemen in here. I'd buy a new rust free shell before I'd bother spending a ton of money on getting it repaired.

 

[95eclipser]

Brave gentlemen in here. I'd buy a new rust free shell before I'd bother spending a ton of money on getting it repaired.

You have a point. But when your in my boat.

99 GSX
80k miles
black interior and built.

Where the only body rust is that passenger strut tower. Ill take the chance to fix it. Hard to find clean shells now.

 

[wishihadatalon]

My wife has had her car for 10+ years. It was the first car she purchased on her own and it was the car she learned to drive a manual with. We have enough disposable income and time that we feel its worth investing in the sentiment. That being said, I often find myself searching for shells as a replacement. I'm going on month 4 or rust surgery for my strut towers, but then again, I drilling spot welds to remove each panel and then cutting out cancer spots, before blasting, priming, welding, priming, filler, paint, etc.

 

[95eclipser]

Well my strut tower arrived at the shop today. Should have my car back by next Friday.

The guys at the shop said miller import supplied more then enough strut tower. Big thanks to them.

 

[Blurred Talon]

Brave gentlemen in here. I'd buy a new rust free shell before I'd bother spending a ton of money on getting it repaired.

Not always an option.

Being on an island, I've got little options for clean shells. Bringing a good running shell to the island would likely cost just as much as having mine all fixed up.

 

[Dsmkauai]

Depends how bad it is. I did mine probably 6-8 years ago and it still looks perfect. The most work is cutting out the old rust to good metal. Then shaping a piece to weld in. These cars arnt being made anymore so gotta save all we can!

 

[Gamble97]

This was my solution to the rusty strut tower problem. Grinder to the rust to clean the surface, 2mm steel scrap metal from work. Cut the sheet metal and welded it together. Painted it with ceramic engine paint from a rattle can.

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umm what? That doesn't even count as being welded.

 

[RevyDSM]

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?

 

[mitsumikey]

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.

 

[wishihadatalon]

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

 

[spyderdrifter]

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.

 

[mitsumikey]

More cutback then shown. Custom made panel from back of strut tower to firewall on both sides. late but nonetheless here we go

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[Sab0101]

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.

What that cost you to get that done

 

[Spleen8urLSX]

What that cost you to get that done

If you read back it appears he did the work himself. You’d be looking at likely about $3000+ to pay a body shop if they’re even willing to take it on.