In my continuing saga of restoring my 7, I have some concerns about the undercarriage. The bottom of the car is VERY rusty. On the driver's side, there is even a hole in the floor where the carpet was tore up and has been rusted through. When I slam my door shut, bits of rust fall off the car onto the ground.

I am wondering what can be done to restore the chassis. I understand it will take a lot of work, but I am just looking for some tips that might make it a bit easier. Thanks.

 

Buy some steel and a welder, start removing rust and replacing it.

 

buy another car

 

i think this wil be the only way you can do it, sand it down to clean metal, and for what not salvagable(sp?) you will have to cut that out, and weld in new metal. you should post pics of how you do it, along with your progress.. so other can see a way to do it...

 

First thing you do is assess the entire car. Get it up on a rack and check everything undernearth for rust. Look specifically at the floor pan, rockers, rear control arm mounts and all the seams.

On the ground pull the passenger carpet and bins, take off the rear wheels.

From your description and location, you have a problem. Once you do the assessment of the repairs needed, you have to decide if it is worth the time, trouble and expense. I've parted decent looking and running 7's, just due to the rust. The repairs would have been more than the car would be worth.

Post pics of all the rust areas, then we can give you better advise on how to approach the body.

 

i dont know if you can repair rusted/damaged unibody supports...any one know?

 

WHat trochoid stated sounds like the best approach. You really must find out if it is worth the trouble to repair the rust areas on that particular car. You said it is VERY rusty and that sounds scary. It is not much fun working with lots of rusty components. One or three maybe...

I have seen reports of other cars here in the forum that were taken off the road due to rust, and they looked great along with many mods. So before you get to that point, which must be very sad, review the entire car condition.

I also read here of California RUST FREE cars that are available at a very good price.

Pics would be nice and also knowing do you have invested in the shell/frame so far would be helpful.

 

Depends on which parts and how good of a metal fabricater you are or can find and how much money you are willing to spend. Steel is steel, so to speak. One of it's best properties is it's ability to be formed and still retain it's strength.

With enough time, tools, talent and cash, any part of the body can be replaced. But will it be worth it? There is a point of diminishing return.