Uhh, the dreaded strut tower rust

[asoomal]

Hello,

So I finally had the chance to take a look at my strut tower rust and this is what I'm dealing with.















As you guys can see, the strut tower reinforcement bracket, the part that is spot welded on to the hood ledge and the strut tower has rusted into the strut tower. (Pitted surfaces).

I was able to drill out most of the spot welds and remove the bracket, but some of it is fused with the tower. Also, after wire wheeling it, and hitting it with a hammer, a few, rather large, holes appeared on the right strut towers.

Besides ordering a new strut tower and hood ledge combo from Courtesy Parts, is there a cheaper alternative to repair this? The brackets can be easily made, its the actual holes in the towers that scare me.

Thanks =)

[Razi]

I guess you could try cut and patching it and grinding it smooth.
Rust sucks

[asoomal]

Just looking through the S13 Body FSM, so many spot welds...

I guess I could just cut it out and weld in a new patch. However, it is a structural piece, does anyone know if it's safe to do that?

[S133P3R]

Maybe wheel tubs?

[asoomal]

Thanks, but trying to keep this stock as I can.

[Jabberwocky]

I fixed a couple rust spots in mine by cutting them out and welding in 16ga steel then grinding it smooth. I don't see why it wouldn't be structurally sound if you can lay a good weld bead...

[adobson50]

Yeah same problem here i honestly dont know what he meant by a bead of weld. dont do that you will warp the s*** out of the metal. Cut it out and put a similar size strut tower peice of metal in put weld through primer on it, put 16 ga metal for your fenderlip and prime and paint. when you weld on auto body you use tack welds. cut ur metal bend it to shap tack one end. tack the other and when you get your corners and end tacked be sure to spray it with some air to cool it down. DO NOT LET YOUR METAL GET HOT AROUND IT! but just start filling in your gaps with tacks spray it a little. basically get the feel for your metal. Dont use gloves! If your metal is to hot for your skin its to hot for its self and it will flex and warp and cause a cluster f*** of wrinkles.

[asoomal]

Yeah about that...
my-s13-was-built-on-a-friday-restoration-t580792.html