ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Technical Discussion - Beginner / Repair => Topic started by: Bear76 on June 07, 2011, 06:07:35 AM
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I was wondering if anyone has any rust repair stories and pics that would help give me an idea of what I got myself into. I just got a 94' and the cargo area is pretty rusted out along every seam. I was just going to start cutting and welding willy-nilly but I came to my senses (wife said) that I should do some research first. I did search and came across a few things not a complete floor/wheel housing/support replacment.
BTW, Im new around here.
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Welcome, now for the rusty part, a 94 Track/Kick or the last Samurai?
I will assume it's a kick because there are not that many Sammys from
the later years. There are a few rust repair stories in the database here
and I am not one that has had to deal with rust issues, I have a rust
free '89 because I live on the west coast in a semi-arid area,t takes
50 years for stuff to show rust out here.
You might start with finding out is there is enough to repair, because
it could get really ugly, and how much you want to fix. I would sand blast
all the rust away, see if there is good base metal to work with, and see if
there any patch panels available from body shop supply stores.
If you are going to keep it you must stop the rust, if it's not all gone it
will keep going, I feel for the East coast guys, this cancer is a pain
Good Luck
Wild
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I feel for the East coast guys, this cancer is a pain
A pain, it's a nightmare!
Here's my article dealing with rust, my floors didn't have any rust, but you'll get the idea.
http://www.zukiworld.com/forum/technical-discussion-beginner-repair/removed-my-bumper-cover-and-found-a-nightmare! (http://www.zukiworld.com/forum/technical-discussion-beginner-repair/removed-my-bumper-cover-and-found-a-nightmare!)
Another article where a forum member replaced the whole rear cargo area can be found here.
http://www.zukiworld.com/forum/build-diaries-how-to-diy/91-suzuki-sidekick-progress-pictures!/ (http://www.zukiworld.com/forum/build-diaries-how-to-diy/91-suzuki-sidekick-progress-pictures!/)
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Welcome,
I too live in a "Fender Flopper" State and rust is a "Plaque" to all vehicles here!!
I don't know your skill level, or what your "Man Cave" has for tools?
SO, PLEASE I AM NOT TALKING DOWN TOO YOU!! Just trying to keep it simple!!
Your going to need some shop tools & equipment that for a "First Timer" add up real fast.
The most expensive is a GOOD!! wire welder.
Next is your "Game Plan"; do you want to Just Fix IT, or RESTORE IT?
Just Fix IT has a lot of options to save the OL' Green Backs.
By your post, it sounds like the rear "Cargo Area" is in sad shape.
just some Ideas for a Just Fix IT repair:
Measure the flat floor area, wheel wells, & etc. Then go out and find a donor pick-up box that you can saw-all a piece
larger than what you will need (This will help later to line up the floor ribs) and all the other items you may need.
Then have fun; hammer, pound, cut, fit it again for the hundredth time, and it about 2 weekends and a couple of 12 packs later......you can post pix here of your success!!
Again, Welcome to the MADNESS!!
CAPT
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I forgot to mention that it was a Samurai. Capt, dont worry about talking down. I do have a MIG and an ARC welder and cabinet full of tools. Im not great at welding but I'm not scared to jump right in with it.
I've mostly delt with K5's (had 6) so rust isnt a too much of an issue. I have always wanted a Sammy but they don't show up around here too much unless you have alot of cash, i dont. Mostly what I wanted to see is what others have done and maybe learn a bit more of how this thing was put together. This will be a semi daily driver, mostly around town no major highways, so i was going to the restore/improve route. I'm not overly concerned about looks just function, but if I can get it to look good too, I wouldnt mind.
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I forgot to mention that it was a Samurai. Capt, dont worry about talking down. I do have a MIG and an ARC welder and cabinet full of tools. Im not great at welding but I'm not scared to jump right in with it.
I've mostly delt with K5's (had 6) so rust isnt a too much of an issue. I have always wanted a Sammy but they don't show up around here too much unless you have alot of cash, i dont. Mostly what I wanted to see is what others have done and maybe learn a bit more of how this thing was put together. This will be a semi daily driver, mostly around town no major highways, so i was going to the restore/improve route. I'm not overly concerned about looks just function, but if I can get it to look good too, I wouldnt mind.
Another idea is to check with your local body shop for replacement panels... There is a company repopping almost all the Samurai body parts.
-Eric
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Well, I just went ahead and jumped in head first. Pulled the tank, found out that I wont be reusing that, full of sludge, pump done for, and sender trashed. Pulled what was left of the bumper, won't be reusing that either. Started drilling out the spot welds that were still holding on. Next weekend I'm going to pull the rollbar and flares. I might start cutting things out but I am trying to pace this out so I don't get overwhelmed by it, little by little.
Good news is that the rear support and corners are in good shape.
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Progress
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"It's only a FLESH WOUND" !!
You'll have all that cleared up in no time!!
By the time that pizza delivery guy finds your place, you'll be ready for PAINT!
CAPT
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Bad pic, but the fender mount on pasenger side seem solid. I need to address the rust behind it, but doesnt reach the spot welds on the mount.
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First I must compliment you on your shop,
It looks like mine........once I jump into a project....ITS MASS CHAOS !!
You already mentioned drilling out spot welds on the rear bumper;
so I think this is your plan of ATTACK here also.
A friend did this same type repair by drilling out the spot welds, after the rust repair,
drilled new holes to "Pop-Rivit" the fender flare brkts back on.
Sorry I was overly optimistic on the limited extend of your "patients" cancer.
But Carry On!!
CAPT
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LOL, I'm just glad these things are so small, doing a K5 in there was a bitch! I had some other projects that I was working on when I started this so they got pushed aside, and ............yea, it's a mess if forgot i wasnt talking to my dad, he's kinda fussy about his shop.
I think I can gently, LOL, get to the rust without taking the mounts off. The drivers side is much worse. Rivits will work but I got a new welder so im going to go crazy with it. The good thing is everthing from b piller forward is perfect, floorboards, fenders, ect dont need anything. The PO must have been used it at the boat dock quite often.
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I don't know where your "At A Secret Government Base" is;
But my 2 bits is; the PO had a "Bikini Top" and left it in the "Elements" for storage'
This could explain the radical difference on the rust damage.
Here in Wisconsin, a soggy carpet with the "THIN STEEL" used on a Sammy, it would be TOAST in no time!!
CAPT
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Secret Base?
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The last pic shows the roof to a chevy work van that may be my new cargo floor. It seems to be 20 gauge, about the same as the Sammy.
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(Secret Base) I don't know where you live on our planet ?!!!
The local weather / climate
CAPT
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oh, I gotcha. I thought my cover was blown.
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While cutting and inspecting I notices that the main body crossmember (just behind the seats) is rotted pretty bad and the mounts are FUBR. I was going to cut out the rockers at some point and weld in some 2x4. I was thinking that I could replace that cross member with 2x4 and tie into the rockers and pans. Has anyone done this?
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Making slow progress. Here is what I will be using for the body mount support, rockers, and rear bumper. I'm tring to use as much free stuff as I can!
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Pallet Racking, Cool Idea !!!!
I love the "Economy Materials Supply House" myself !! (Dumpster Diving)
Very strong and light weight. Post how it welds up ?
Bed frame rails are tough as nails, need a good deep penetrating stick to get a good weld.
CAPT
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I sure will! I have a couple of theses that I will bringing home in the next few days. I never thought about bed railing, I'll have to keep my eye out. We have another work van here that we will be scrapping soon, I will be cutting some panels off before it goes.
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Slow progress
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Slow day at work, Just made myself a 52" wide metal brake 8). Once I mount it I will share some pics. Now I can bend my own floors and wheel wells ;D.
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I would have kept that secret to myself.
Now everybody will be looking for your "Secret Hideout" to come borrow it !!!!!
CAPT
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Its been a while, but here is the bender in action. this is 16 gauge 50" wide. I am rebuilding the floor from the e-brake back.
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a little progress
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Trailer Fenders
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Nice use of the trailer fenders. I cut out my inner fender well and welded in a flat piece to replace it. The extra clearance in the back is rather nice. :)
https://picasaweb.google.com/105298426119042245963/Misc#5473188570020331394
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I was going to try that but the fenders were too far gone. I am going to raise them up about 6 inches though. As they are now they are just as tall as the bed rails.
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Are you going to trim the outer fender that high as well?
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Thats what I was planning. The factory flares caused the body rot about a good 3 inches all the way around. the new fenders will get spot welded to the outer body and then I will roll them to give it a finished look. I still want to run some sort of small flares, I've been looking into this but haven't made a decision.
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Still chugging along, keep finding more rust. Any ideas on how to "finish" these rockers, they are just propped up right now.
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Putting the step in there is pretty cool.
BRD HNTR replaced his rockers as well, you can read about it at http://www.zukiworld.com/forum/build-diaries-how-to-diy/tracker-2x4-rockers-frnt-bmper-4-dr-sprngs-lwered-frnt-diff- (http://www.zukiworld.com/forum/build-diaries-how-to-diy/tracker-2x4-rockers-frnt-bmper-4-dr-sprngs-lwered-frnt-diff-)$30-steel-frnt-diff/