Chassis Rust MK2

[CarCrazy73]

Hi,

I've only had the car a couple of months but I've done the trackday and hillclimb school in it I bought it for. And it survived...

Anyway its got a months mot left so I thought I ought to start checking it out to see if it would pass. The rear arch is going but its solid under the sills so probably ok for this years mot. It runs, drives and stops perfectly and hasn't missed a beat since I've had it, even on track. And its been thrashed. When changing my brake pads after the trackday I noticed the outside of the drivers chassis rail was a bit swollen, crunchy when pressed and had been covered in cheap underseal so I thought I'd start there. I jacked it up at the weekend, removed all splash shields and wheelarch guards and aggressively jetwashed the chassis / engine bay area. A couple of holes appeared after this..

After Jet Wash Drivers Side

After Jet Wash.jpg (210.76 KiB) Viewed 13926 times

Underneath of passenger side chassis rail

Base Passenger Side.jpg (197.92 KiB) Viewed 13926 times

After a bit of hammer and wire brush use it enlarged - you can probably go a good inch round what you can see before good metal

Hammer and Wire Brush.jpg (191.42 KiB) Viewed 13926 times

I was thinking (before starting) I'll just plate it up if theres a couple of little holes. I think its now way beyond that. The amazing thing is initially (should have taken pic...) there was no visible hole or crack, just a bit of swelling

Do we think it is worth repairing?

I keep thinking I only paid £675 for it, I've done what I wanted in it, its still got a months mot and I could probably get £300 - 400 back for it off someone making a westfield or similar...
The other side is saying I'd forgotten how much fun they are, I have become quite attached to it and I don't like killing them or giving up easily.

I'm just worried it could spiral into allsorts of other jobs on the way and I'd have been better just getting rid and spending the money on buying a better one?

[flea]

They are bad but I'd save it. Just cut them off & get some new ones welded on. Then you know you've got one with good rails

[blackyb]

They are bad but I'd save it. Just cut them off & get some new ones welded on. Then you know you've got one with good rails

Totally agree, the replacement sections are quite cost effective and if done right and protected will last for years.

[Mazda Mender]

Get it done correct with repair sections( we sell them on here) the rails are a cheaper fix than the rear arches and sills,,,cosmetic to us now.
M-m

[CarCrazy73]

Ok, thanks for the advice, you've convinced me to have a go!

I've looked through a few repair threads on here and have a good idea of what to do. I've ordered some anti roll bar drop links and I'll get some of the repair sections for the chassis rails

I jacked it up again yest for another look and to spray some wd on everything again. My main concern is the bolt through the top wishbone. The nut is very corroded and does not look like it will want to come off. I tried a few spanners on the nut and the bolt head and even the ones that fitted the best seemed a bit loose. I know once they've slipped your in trouble. Can anyone confirm the sizes for me before I start rounding nuts off? The bolt head appears to be a 21 and the nut a 20 but neither are a brilliant fit, I'll get some decent 6 point sockets before I start

Top Wishbone.jpg (214.33 KiB) Viewed 13892 times

If I cant get it off I was thinking I can probably get a small grinder in on the nut to cut it off? Is that the best way if it wont move? Or am I worrying about nothing? I've seen a couple of 2nd hand bolts on ebay and ordered those in case I have to cut them off

Thanks,
Andy..

[blackyb]

Ok, thanks for the advice, you've convinced me to have a go!

I've looked through a few repair threads on here and have a good idea of what to do. I've ordered some anti roll bar drop links and I'll get some of the repair sections for the chassis rails

I jacked it up again yest for another look and to spray some wd on everything again. My main concern is the bolt through the top wishbone. The nut is very corroded and does not look like it will want to come off. I tried a few spanners on the nut and the bolt head and even the ones that fitted the best seemed a bit loose. I know once they've slipped your in trouble. Can anyone confirm the sizes for me before I start rounding nuts off? The bolt head appears to be a 21 and the nut a 20 but neither are a brilliant fit, I'll get some decent 6 point sockets before I start

Top Wishbone.jpg

If I cant get it off I was thinking I can probably get a small grinder in on the nut to cut it off? Is that the best way if it wont move? Or am I worrying about nothing? I've seen a couple of 2nd hand bolts on ebay and ordered those in case I have to cut them off

Thanks,
Andy..

Get a good set of six point sockets, throw out the multi fits, plenty of WD40 (there are other brands available) and take your time.

[Mazda Mender]

21mm buddy.
M-m

[ne.ross]

this is what my chassis rails look like to, i am going to get the repair sections welded in and hopefully sort the problem out