Before anyone bitches, it's not a full car project, just a specific repair.
Welcome to Project: Rusty Shackleford.
This is a terrible idea, I should have scrapped it.
Wicked has a thing for completely hopeless projects he will waste entirely too much time and money on.
I strongly recommend getting a tetanus shot before reading further.
Background: The girlfriend's first car, an 88 fox LX notch. I advised her against it, but it was love at first sight and she bought it anyway. Rust was one of the many, many issues with it. After a couple years we pulled it off the road because it was getting so bad, in favor of a 91 fox.
We've had quite a few people poking around asking about it. We could have sold it to some unsuspecting poor bastard with dreams of an LS fox (like the poor one we bought it from), or better yet crushed the damn thing, but here I am again, thinking "I can save this. I can do it" on another lost cause.
Let's begin, shall we?
Engine out, we can see the notorious fox strut tower rust, and then some.
Then I start picking at it with a screwdriver. It's waaaaay worse than I thought.
Yeah, that came apart with a screwdriver. No cutting necessary.
Diagnosis: Car was held together with PFM. Pure Fucking Magic.
Next step is cutting and cutting and cutting all the rust out until we get back to good metal. And it's a lot.
What makes it worse is the way it's built. It's not like a single tube welded to panels. It's multiple layers of stampings all spot welded together to cut costs. That means lots of drilling and cutting to get to where you want, and lots of thinking of how to reconstruct what you're slicing to ribbons. It's especially a pain when you have to cut and remove the rusty inner layers, even if the outers are fine.
Where it sits now, with a lot more to go:
Still needs some cut out of the strut tower.
I'll have to weld on the inners and strut towers, then drop the K-member, do the bottom, outer, and top, section by section.
How I feel taking on this project: