Frame rail replacement

[SVOsocool]

I bought this car two years ago just a few days before I found out my wife had cancer and it has been on the back burner since. She has been hounding me to get it on the road again and fixed up so I feel really motivated right now. I have finally gotten around to trying to get everything done on it and found some really bad rust on the front drivers side frame rail right where the front sway bar is connected. I knew it had some rust, but the rust is a lot worse than I first thought and the rail is going to have to be replaced from the radiator support all the way back to where it starts to bend downward at the firewall. I know people have replaced whole front clips and rails before and I have a 79 Capri to get the rail from. How expensive and difficult is this going to be roughly? I really can't afford a huge bill from a body shop, but I am no body man and couldn't possibly do the work myself. I have a friend who does a little body work and welding on the side and is trying to learn on his own. Would this be a good project for him to try? What all needs to be removed up front other than the obvious small items and wires? If it were any other car I wouldn't go through the trouble, but it is an SVO and a 4e at that. Any help would be greatly appreciated.

[Joe P]

I APPLAUD YOU!!

SVOsocool, I have a race SVO and had thought about an double A arm front suspension for this winter. I have to say that even on a race car, it would be a major undertaking from my veiwpoint.

No offense to your buddy with trying his welding skills, but I have a race car fab shop do all my welding and can sleep at night knowing the weld penetrations are perfect. I might add on a street going car that is subject to all kinds of nasty, the quality will need to be there.

Gee, I hope I didn`t deter you ( doubt I did ), as it is wild to see you take on saving her I, as well as MANY would love to see it in any state of condition!

Hope all is well with your family.

Joe P.

[SVOsocool]

Man that is really not what I wanted to hear. I have the worst luck buying Mustangs. I really wanted this SVO and probably clouded my judgement as to what needed to be done to it. I really wanted a green one. Well....I guess I'll just have to figure out where to go from here. Any Idea how much it might cost? I didn't pay as much for my car as I would have if I had bought a nicer one, but I guess I paid too much considering what needs to be done to it. On the bright side, it ran real good and drove great. I was just afraid to push it because the sway bar was not attached and the rust scared me some. When the engine came out and I could get a good look at the rust, I about passed out. At least all the rust is confined to the rail and it did not spread into the metal all around it. I doubt I will be able to afford to fix it up anytime soon. At least my dad has 26 secluded acres and a covered carport I can put it under for a couple of years if I have to. I have some pics at the house that I can post to show you exactly what kind of damage I'm talking about.

[AT6svo]

A picture is worth, well, more than 1000 words. Take some pics & post them. It will be much easier to tell actually how bad the rust is in the affected area. It almost sounds like it was due to battery acid exposing the metal, then the rust/oxidation began.

Do not be too discouraged. There is nothing that can't be fixed. Its all about time vs effort vs money. Which of the three do you have most of? Your car being a 4E surely appears to be worth it. As long as the damage does not extend into where the cross-member bolts up (i.e. where the major support and forces exerted onthe unibody are generated) you should be ok.

Post the pics, then speculation is out of the question.