OK so I've seen this rust throughout my build and always thought it wouldnt be a problem... until when its getting close to being road worthy. Anyways ESSENTIALLY: This rust has to be fixed and there is no part out option. I already put the 4 link and cage in. Heres some pics

These first two pics are of the rust on either side of the windshield near the mirrors (A-pillars?)

 

heres the pics of the rust on:
pic 1 and 2.) the rust by the t-top latch thingys

pic 3.) might be the worst of all. The rust on the drivers side corner by the B-pillar

more to come

 

The final two pics are of the bad surface rust by where the t-top seals would be. The roof is not looking like its gonna be a fun fix, if any rust is a fun fix!

SORRY for the bad pictures. It seems like my camera didn't focus well.. maybe cause I dropped it about 17 times too many

 

What i would do is use a grinder with an 80 grit flap disc and knock off all that rust and paint. If its just surface rust the flap disc will take it down to bare metal and leave a smooth, shiny surface. If the rust is deeper and you have holes then you might use a fiberglass repair batch or have a small metal patch welded in place. I doubt this would be structure problem and it can be fixed easily. This is for the A-pillars.

The other areas are bad and you will need to weld in some patches. Either use metal pieces and make small custom patches to weld in or look for a wreck car to cut the pieces out and weld in.

I have done patches on my rear wheel wells and fix it nicely.

 

OK! thanks! I'll probably pick up some 80 grit discs this week then. Would I be able to a disc on like a buffer or something, I just downsized garages majorly and now I don't have 220 and I have this half *** 110v air compressor.

 

When it comes to grinding rust and metal, I picked up a Porter-cable grinder at Lowes for around $30 and it works great. I'm not sure if some buffers or sanders will use the Flap discs. Grinding wheels are usually 4 1/2 diameter.

 

I actually have that exact tool but I wasn't sure how much air it used. I'm thinking my compressor is way underpowered. Yours is pneumatic right?

 

Its 120v electric. Its a typical grinder you'd find at Lowes. I use only my air sanders for body work(sanding and moving paint).

Your b pillar area will need to be grinded and cut out. A repair like this would need pieces to be cut out and welded in. I use small pieces of cardboard to make my templates and use for the sheet metal to cut out and fit proberly.

 

Ok, thanks! I just sold a couple parts today so I'll probably be goin to buy the grinder and discs tomorrow and post some new pics of the pilllars tomorrow also. I'm anxious to see what lies underneath cause it feels like someone tried to caulk fill it before or something, its all sticky and stretchy...

 

From your description the rust is caused by the moisture trapped by the foam in the A-Pillar (see my other thread below). Best bet may be to cut out the rot since it is likely rotted from the inside out.

If you grind all the surface rust away and fill the spot it will be back in a few years (if not sooner).

https://www.thirdgen.org/forums/body...de-pillar.html

 

Yea i think a battery powered cutoff wheel at the junkyard might serve you well in this case, they you can tig weld the peice in and be done with it.

Seriously, that hole doesnt look like rust, looks like someone tried to hack thier way into your car heh...

the fiberglass patches work good also, i can vouch for those. Patched my Nova and 7 years later it was still holdin strong.

 

Ok, thanks. Ill post a pic of the other pillar. I didnt realize i posted the same pillar twice. But now that i go and look i have to edit because I only have the one pillar! The drivers side one is way worse