The New Project: Part Deux!

[njsteve]

In looking at the frame rail damage/rust it doesn't appear to be as bad as I initially thought. (I hope).

The undersides of the lowest portion of the rear rails by the front leaf spring pocket both have the outer layer corroded on the bottom and sides. It is also evident on both inner and outer sides of that area, next to the E-brake cable. There are three separate panels that sandwich together at that point and it looks like just the outer one held the crud and rusted, as this is the lowest point on the rail (lower than the drainage hole unfortunately). It also didn't help matters that the delivery truck driver used that spot as the hold down for his cargo chains. [img]<<GRAEMLIN_URL>>/rolleyes.gif[/img]

Pass side:



Driver's side:

[njsteve]

The other rail problem was in the rear where the aftermarket exhaust had all it's weight on the tailpipe hangers after the crummy, universal hangers that were sheetmetal screwed into the rear bulkhead, ripped out. It appears that the reinforcement section of both rails were not properly tack welded in originally, as the pass side area pulled away and cracked the frame under the panel.

Pass side:



Driver's side:

[njsteve]

And the solution:

I bought a pair of the new reproduction frame rails to use for donor sections.





I also bought a set of the repro sway bar mounting brackets as the ones on the car have been welded so many times, they actually welded a bolt across one of them to keep it together.

[Dave Rifkin]

and so it begins...........again. Can't wait to see how nice this one turns out. I am amazed at the knowledge and skills that so many people on this site possess.