This is a step-by-step thread on how I repaired the rust on my 90 240sx with 95k miles on it from New York. Even-though I live in ohio I got the car from a dealership that had got it from there. This will be multiple posts with this one being the start and I will continue until I am finished with the repair. I am currently as of starting almost done, but I only have time to type just the before stages.
First we have the battery box, I suggest tearing it out and relocating the battery to the trunk, but do a better job then me tearing it out. note: picture taken after removal
Next the frame railsdriverspassengers
Then the transmission tunnel, both sidesdriverspassengers
Finally a couple other spotsdrivers wheel wellradiator mount
There was also four other spots the needed repair. On the drivers and passengers side front where the jack location is the rust was bad. It was also bad on the drivers and passengers side rear wheel well right after the quarter panel. Both these spots will be in later in-progress pictures.
Next Up, Repair Stages
Rust Repair Write-up
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glacier985
- Posts: 390
- Joined: Fri Jul 18, 2003 4:30 pm
- Car: 72 Datsun 240Z
90 Nissan 240SX
11 Subaru WRX Wagon
16 Nissan Rogue - Location: Central Ohio
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glacier985
- Posts: 390
- Joined: Fri Jul 18, 2003 4:30 pm
- Car: 72 Datsun 240Z
90 Nissan 240SX
11 Subaru WRX Wagon
16 Nissan Rogue - Location: Central Ohio
Re: Rust Repair Write-up (glacier985)
Next Step,First the tools I used:
HammerScraping devicePicking deviceDie Grinder w/air compressorMIG WelderWire BrushDremelGrinderRust-Mort
About the rust-mort, if your going to do rust repair I suggest you get ahold of some. Its the best thing created for this, its an acid the litterally kills the rust and turns it black. You can paint over it with primer and if done right the rust will not come back. I got it from the repair shop I work at.
Now what I did was go around and first try to get every bit of rust out I could by hitting, picking and scraping the spot. I then went back around and cut out the rust that I could with the Die Grinder. Next I went back through and took a wire brush and the dremel with a wire brush end on it as well and got off everything around the rust spot also hit what I could with the grinder and then put some of the rust-mort on it. The next step is too weld the patchs on after priming everything including the patch front and back. Some in-Progress pictures
Next Up, Patching Process
Mods, if this is in the wrong forum and may be more apporiate in the 240sx main forum feel free to move it
HammerScraping devicePicking deviceDie Grinder w/air compressorMIG WelderWire BrushDremelGrinderRust-Mort
About the rust-mort, if your going to do rust repair I suggest you get ahold of some. Its the best thing created for this, its an acid the litterally kills the rust and turns it black. You can paint over it with primer and if done right the rust will not come back. I got it from the repair shop I work at.
Now what I did was go around and first try to get every bit of rust out I could by hitting, picking and scraping the spot. I then went back around and cut out the rust that I could with the Die Grinder. Next I went back through and took a wire brush and the dremel with a wire brush end on it as well and got off everything around the rust spot also hit what I could with the grinder and then put some of the rust-mort on it. The next step is too weld the patchs on after priming everything including the patch front and back. Some in-Progress pictures
Next Up, Patching Process
Mods, if this is in the wrong forum and may be more apporiate in the 240sx main forum feel free to move it
Re: Rust Repair Write-up (glacier985)
hey i am out in aurora.. you should stop by and look at my 240. i have the same problems as you!
take it easy, hope it goes well!
take it easy, hope it goes well!
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superDorifto
- Posts: 1306
- Joined: Mon Jun 13, 2005 1:13 pm
- Car: 1997 Eclipse Spyder - AWD/5spd swap in progress
1995 Q45 - 5spd swap in progress
1984 200sx hatch(KA-t swap) - 355WHP
1991/1993/1995/1997 240s - Dead
1982 200sx hatch - fixed/scrapped - Location: CT
Re: Rust Repair Write-up (slo9012ve)
good start man, i want to see what it looks like when its finished. I live in Connecticut, so trust me i feel you on the rust issue. I just picked my 240 up for dirt cheap ($400) but it has HORRIBLE rust. the rear passenge quater panal is gone at the bottom, and in the engine bay the shock towers have completely seperated from the frame rail on both sides! in a few weeks, when i swap in the new transmission and motor im going to be not only patching but reinforcing those panels. good luck with your removal. ill post some pics of mine when its done too.
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glacier985
- Posts: 390
- Joined: Fri Jul 18, 2003 4:30 pm
- Car: 72 Datsun 240Z
90 Nissan 240SX
11 Subaru WRX Wagon
16 Nissan Rogue - Location: Central Ohio
Re: Rust Repair Write-up (superDorifto)
its actually completly finished I just ahven't got around to posting the finished pictures. They should be up later tonight or tomorrow.
superDorifto it sounds like yours will be a big job. I think it would be good to add your pictures as well, since everyones rust problems will be different.
superDorifto it sounds like yours will be a big job. I think it would be good to add your pictures as well, since everyones rust problems will be different.
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superDorifto
- Posts: 1306
- Joined: Mon Jun 13, 2005 1:13 pm
- Car: 1997 Eclipse Spyder - AWD/5spd swap in progress
1995 Q45 - 5spd swap in progress
1984 200sx hatch(KA-t swap) - 355WHP
1991/1993/1995/1997 240s - Dead
1982 200sx hatch - fixed/scrapped - Location: CT
Re: Rust Repair Write-up (glacier985)
i plan on posting them, i got the car up on a lift today and really checked every nook and cranny for rot. im lucky, ive only got patch in three spots; the left and right fender wells where they meet the frame, and a small spot about the size of a playing card directly under the driver on the bottom of the frame. im gonna check with some local shops to make sure i get the right gauge steel first. im also waiting until i get my 5spd swap all together because it will be 1000x times easier to do a quality job on the fenders with the motor and transmission out. expect lots of pics in the next few weeks....
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glacier985
- Posts: 390
- Joined: Fri Jul 18, 2003 4:30 pm
- Car: 72 Datsun 240Z
90 Nissan 240SX
11 Subaru WRX Wagon
16 Nissan Rogue - Location: Central Ohio
Re: (evildky)
I guess so, I'm using the stuff we use at the shop to restore cars. And we have a lifetime warrenty on what we fix.evildky wrote:you are using a zink/weld through primer right? regular primer will melt off on the inside when you weld in your patch panels
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glacier985
- Posts: 390
- Joined: Fri Jul 18, 2003 4:30 pm
- Car: 72 Datsun 240Z
90 Nissan 240SX
11 Subaru WRX Wagon
16 Nissan Rogue - Location: Central Ohio
Re: Rust Repair Write-up (glacier985)
almost to the final step, but first some pictures of the spots I patched. Theres not much to this step, weld patch, grind weld, primer,cover with caulking to smooth the welds and then final primer and paint.
and now some finished pictures
The other parts I had rust problems were the inside of the quarter panels, the piece of metal that runs along the outsides of the car was bad near the jack pints and the a-arms. Everything else was on the suspension which will either be replaced or took of. sandblasted and painted in the future.
and now some finished pictures
The other parts I had rust problems were the inside of the quarter panels, the piece of metal that runs along the outsides of the car was bad near the jack pints and the a-arms. Everything else was on the suspension which will either be replaced or took of. sandblasted and painted in the future.
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lonelywanderer
- Posts: 113
- Joined: Sun Apr 03, 2005 5:33 pm
- Car: 91 240sx coupe
Re: Rust Repair Write-up (glacier985)
looks good....
Re: Rust Repair Write-up (glacier985)
thats nice but did you check the base of the driverside strut tower. thats the worst spot on these cars because dripping brake fluid eats the paint off.