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Old 07-28-2017, 06:20 PM   #111 (permalink)
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Topoff (RIP) - '92 Geo Metro LSi
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Quote:
Originally Posted by Daox View Post
I await rusty pics.
I await repair and result pics....maybe it will reassure me that I can do the same!

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Old 08-02-2017, 02:38 PM   #112 (permalink)
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Blackfly - '98 Geo Metro
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Mmmm... choco delish!

The passenger side, cut back to clean metal. Just one hole, and not too bad:




Choco delish patch template!

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Old 08-02-2017, 02:42 PM   #113 (permalink)
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Blackfly - '98 Geo Metro
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Last 3: 70.09 mpg (US)

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Flintstones! Meet the Flintstones!

The driver's side was unsurprisingly worse than it looked at first glance.

Here it is, sawzall-cut back to good metal.



FORTUNATELY! The edges of the cut are where the metal is thicker/structural and so slower to rust away. So there's a good "border" to weld to, almost all the way around.

That section running down the middle of the footwell is an underbody "frame rail" - a box channel stiffening element, also made of thicker metal. It needs a bit of first aid.

Based on what I'm seeing, I bet someone probably sells pre-fab floor patch panels for this car. Of course, I'm just going to cut & paste scraps of sheetmetal I have laying around.
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Old 08-07-2017, 10:41 AM   #114 (permalink)
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Blackfly - '98 Geo Metro
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Rust repair progress

I made some progress this weekend!

I borrowed some steel boat stands to get the car up nice and high to work underneath:



Of course, the more I worked, the more bad metal I found. (The latest is a hole behind the plastic fender liner.)



But the floor itself is now mostly done, aside from cleaning it up, sealing, painting & undercoating.




I'm not going to win any welding awards. But it'll do the job.
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Old 08-07-2017, 12:24 PM   #115 (permalink)
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broke my fist bolt...

... and my 2nd, 3rd and 4th!

Up to today, I've been pleasantly surprised at how easily the nuts & bolts on a 27 year old car could yield to a wrench and a bit of penetrating oil. (Thanks to not being winter driven.)

But this fender did not want to come off easily!



Unfortunately, I found more future welding work hidden beneath it...

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Old 08-07-2017, 03:42 PM   #116 (permalink)
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Reminds me a lot of the work I did on my Metro.
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Old 08-08-2017, 08:57 AM   #117 (permalink)
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Wow. You are next level masochist.

I was getting frustrated working on my car after breaking the suspension tower studs and discovering my sway bar bushings had crumbled away after spending several days redoing a bunch of wiring, and here you are with a car that makes mine look new patching all that rust like it's nothing...
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Old 08-14-2017, 04:20 PM   #118 (permalink)
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Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 50.45 mpg (US)

Winter beater Metro - '00 Chevrolet Metro
90 day: 50.65 mpg (US)
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2 weeks later...

Rust repair is nearly done.

I have 2 small patches to finish this evening, then it's time to clean & seal the seams, paint (inside) and undercoat (bottom).

Quote:
Originally Posted by Daox View Post
Reminds me a lot of the work I did on my Metro.
But with much messier welding!

Quote:
Originally Posted by serialk11r View Post
Wow. You are next level masochist.
Supposedly the masochist enjoys the pain. That definitely doesn't apply to me -- I'm sick & tired of working under this car and happy it's nearly over!

It occurred to me early on in this process that even at $700, I definitely overpaid for this car.

Part of this is my own fault: I work so slowly. I bet this is a weekend's work to someone with more experience. (And a work ethic!)
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Latest mods test: 15 mods = 15% MPG improvement: A-B test, 2007 Honda Civic 1.8L, 5-speed
Ecodriving test:
Manual vs. automatic transmission MPG showdown: Nissan Micra 1.6L



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Old 08-15-2017, 01:57 PM   #119 (permalink)
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Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 50.45 mpg (US)

Winter beater Metro - '00 Chevrolet Metro
90 day: 50.65 mpg (US)
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Welding is done! Seam sealing done! Undercoating done!

Pics to come.
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Latest mods test: 15 mods = 15% MPG improvement: A-B test, 2007 Honda Civic 1.8L, 5-speed
Ecodriving test:
Manual vs. automatic transmission MPG showdown: Nissan Micra 1.6L



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Old 08-15-2017, 06:24 PM   #120 (permalink)
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Cool!!
I wouldn't even dear to start a project like this
What kind of sheet metal did you use?

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