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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: ghd23 on September 20, 2005, 08:51:13 PM

Title: Rust-Rust and more Rust! How to do it yourself and like it!!!!!
Post by: ghd23 on September 20, 2005, 08:51:13 PM

Hey Guys.  Seeing how my 90 Tracker has always run perfect and the body was always really clean, I was really  :o to see all the rust that was under my carpet.  So today I pulled out the seats, carpet and pad only to find, u guessed it!  A ton of rust.  So I went ahead and cut out the whole rear floor.  Tomarrow I will start taking pix of the project from front to rear. I will give a complete tool list and material list and give step by step instruction on how to repair it right, with all steel panels.  All panels will be made by me, so I can give all details.  When I replace the rear floor I'm going to show you how to make an excess panel to get to the top of the gas tank, which will make everyones life a little easier!  Once I have everything tack welded in place we will move to the front floors.  After all panels are cut and fit up and tacked in place the real welding will begin.  So stay tuned!   Thanks George;

Title: Re: Rust-Rust and more Rust! How to do it yourself and like it!!!!!
Post by: keith on September 21, 2005, 09:24:54 AM

How bad is the rust?  I have only looked at my rear floorboard and it wasn't too bad.  See the thread titled 'fiberglass rust repair'  You make me scared to look at the front!

Title: Re: Rust-Rust and more Rust! How to do it yourself and like it!!!!!
Post by: SnoFalls on September 21, 2005, 09:39:54 AM

The VERY first thing I've done to both trac/kicks I've bought is to pull the carpet. The pad absorbs moisture and never lets it go ... If you insist on carpet, at least pull the carpet, strip away the pad, clean any sign or surface rust (with a little primer on the now bare metal), and put the carpet back without the pad.

I've been lucky that I didn't have rust issues (other than a spot or surface here and there).

For rust through ... there are 3 approaches

1) cut away and weld in new. This is the only proper way if the metal in question forms a structural part of the body.

2) cut away and pop rivet new metal. A decent way to get the holes covered. Use of seam sealer and/or fiberglass can ensure a completely sealed repair.

3) fiberglass patch the spot. This is a quick means of sealing it up, but you WILL be dealing with it again (especially if you didn't cut back to solid metal), since it's likely to continue to rust and/or crack.

Title: Re: Rust-Rust and more Rust! How to do it yourself and like it!!!!!
Post by: ghd23 on October 19, 2005, 04:20:35 PM

Just bringing this up top so You can read part 1, 2, 3

Title: Re: Rust-Rust and more Rust! How to do it yourself and like it!!!!!
Post by: ghd23 on October 20, 2005, 10:14:21 AM

Sorry, No fiberglass for this kid. Always repair steel with steel is my motto.