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1975 rust belt wonder


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Thanks TK.....its definitely a learning experience. The best way to rationalize this project is,,,,,"hey it cost me $900". Give me a little more time and this rail will look way better.

Thanks for the kind words.When they look better, you will be the first to have one.


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  • 3 weeks later...

The drivers side is almost complete, I need to add reinforcement to the main join. Working in these temperatures is difficult (to say the least), therefore the progress has been blindingly slow!.

Two patches were added to repair the rail. Zero-Rust was used liberally inside the frame rail. I have switched from Rust Bullet to Zero-Rust as,

1. Its cheaper, you get everything you see in the picture for $50 shipped! where as one Quart of RB costs that.

2. RB is a pain to work and I am not entirely happy with its adhesion quality...It works great on Rust but new metal needs alot(read more then just wire brushing/ 60 Grit) of prep work...

3. RB is useless once opened.

4. RB has some very critiical timelines you need to follow, which is not always practical.

5. Hold your breath with RB, even a top grade respirator seemed inferior for this!.

I understand that ZR may be inferior and similar in chemical composition to rust-oleum, but its easier to spray/ touch up. WE WILL SEE .....

Anyway back to the work....






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Today the weather was insanely warm, it was 49!!. To celebrate I worked on the rust bucket...

All the repairs utilize 16 guage instead of 18....( Reason: I have a ton of 16!! and no 18). Obviously it will be harder to weld and harder to shape....

This project has a new completion date...2022.






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Pretty self explanatory really.....apart from the fact the welding was done inside out....easier than welding on my back! and all welds will get liberal amounts of seam sealer...so no big deal I guess....Also the floor patch was plug welded to the rail just like the original ( thought I would mention that as its hard to see...



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  • 1 month later...

Amazing work man. I havn't the skills... What art of Indiana are you in?

You should join our Facebook group.. I started it for OH, KY, IN, MI 2002 owners. Its been great so far, we are just getting it started. Check it out.


I am planning a get together for OCT. 3rd. You should come! The info is posted on the group page..

2002 newbie, and dead serious about it.
Smart Audio Products for your 2002


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Thanks Eurotrash,

I have been watching your build with great interest. Your recent seat refurbishment looks awesome.

With regards to your comment about not having the skills, I am sure you do....Like most things in life "dont worry about failing first time round"....

And yes I will join the facebook club....now that the terrible terms of service have been amended LOL..

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