Alright guys and girls,
I've decided to tackle the rust on this thing. it's got all sorts of rust all over the place; in order of severity, the rear subframe is ruined, the frame rails near the gas tank are goners, the rocker panels are non-existant, the front fenders and rear wheelwells are rusting away, and there's surface rust here and there. I don't mind it so much since I basically bought the car to learn bodywork, and since the Union at work has a policy on me Anyway, onto the first thread in this series : the subframe!
The part : The one I've got on the car right now is rapidly becoming dust. I grabbed one at a junkyard a while back; it wasn't very clean since i live in the rust belt, but for 80$ CAD I couldn't really say no. It was the cleanest I could find in the pull yard and I didn't want to buy it new : I need a project to improve my skillset anyway. as soon as I got it home, I sat down and brushed off most of the loose scale with a welding brush. thankfully, mostly surface rust. there's even some original paint on it here and there.
The short list for this little project is to grind and wire wheel off any rust,
MIG in some 1/8th inch steel to replace the original (now rusted away) reinforcements (should I be using weld-thru primer?), coat the whole thing in some rustproofing (I heard good things about POR-15? Opinions? Alternatives?) and throw it onto the car with all new hardware, end links and bushings which is going to be necessary; some of the bolts are so rusty the nuts actually flaked apart as soon as I put torque on them.
I'm making this thread for informative purposes for the next poor guy down the line and because I need your help. Any bodywork advice for a novice would be most welcome. I'm also going to assemble the part numbers and/or bolt specs (thread, size, length, etc) here for future reference for the aforementioned poor guy. As i find these out, I'll update the thread. if you guys know specs or part numbers, feel free to chime in.
The rear 'cam bolts' that are used for the alignment on the flat bars are shared with a 2011 Ford Focus, part number 6S4Z-5K978-AA. I'll need two of those.
I haven't found the part numbers or bolt specs for the rear subframe's boxed arms yet. if you guys can help i'd be glad!
I haven't found bushing part numbers or specs either for the arms
Update : that's because they apparently don't exist. Apparently they were never meant to be replaced to begin with!
Update : According to Jaged & B3NN3TT, the sport package sway bar is the same, stock diameter as the regular cars; 17mm.
I've got some of the subframe-to-body bolts, and arm-to-knuckle bolts (both types) here; i'll see if the Fastenal guy can figure out what they are.
thanks a lot guys! I hope This'll turn out well!