Uni body rusted, saved my z from junkyard

[ZcarsRock]

My beloved 1972 240z had rusted thru the frame rails and front rails under the front cross beam so bad that i was advised to junk the car or part it out. I was determined to save it so i did the following. I took 7' length of 21/2 by 1/4 inch weldable steel and forced into the frame rail slots then drilled holes to bolt it to the strut housings and also holes for the sway bar. I then used a grinder to get rid of the worst rusted areas, then i bought 4 cans of "great stuff" expanding foam and filled the hollow frame rails till it started oozing out. I let this mess dry for a day then i took a ginsu knife and trimmed the excess foam off. Then i painted it with flat black primer, then i sprayed with rubber undercoat. My car has no squeeks and is quieter. I also filled in the area under the battery with foam...just for the heck of it, as rust was eating into the fender. Whadaya think? Am i whacked in the head? is there a better way? or what?

ZcarsRock.....even for us poor folk:)

[Rob]

From my understanding of what you described you may very well be mad, good sir.

But if it was stuffed anyway then why not?

I'd love to see some pics!

[carguyinok]

Wow, hmmmm

Thats A neat trick that the not so good used car dealers used. Looks good but thats about it.

Just make sure you dont hit any potholes or speed bumps going faster then 2 or 3 mph.

If you sell this car make sure you tell what you did. Someone could get hurt or :dead: When it snaps @ the firewall. And it will maybe not today or tomorrow but it will.:sleepy: Sorry.

But hey ENJOY IT WHILE YOU CAN :classic:

[2ManyZs]

If it is really your beloved 72 as you state, you really need to fix it correctly with new floor pans and frame rails before it falls apart and ends up putting you in the hospital or something even worse.

I really hate to hear the word "bolted" when used in reference with a unibody repair.

If it were my car it would either be fixed right or scrapped by now.

Sorry, but you shouldn't make something like this public if you don't want to hear other peoples opinions, especially ones that chastise you for something as irresponsible as this. I doubt that the car is safe to drive. Period.

[Cuong Nguyen]

I have to agree with all the guys,

the car is not safe to drive on public roads!!!

If you want to repair the frame rails properly there are suppliers that sell replacement metal parts that you can weld in, they aren't all that expensive (especially when its a critical safety related item).

Here is a link that you can try to source the parts required:

http://www.datsunzparts.com/emblem.html

I know that you want to get the zed back on the road, but doing it is the WRONG way to go about it. Its like if I was in a mad rush to get my RB26DETT 240Z back on the road and skimp on upgrading the brakes and suspension, that is wrong!!!!

Sorry for the ear bashing, but I dont have time or respect for bad repairs that can lead to fatal injuries to yourself or other parties.

Anyway good luck and hope that your car doesn't sag or walk like a crab in the future

[ZcarsRock]

1st, i am the only one who drives my car. I let my wife ride with me but i never go over 65mph. Hey i was at t traffic light in Topeka last saturday, and some dude and his gal pull along side me in there BMW M3, ( bout a 98 or so) anyway he starts to rev is engine, so i think Game on!!! I dont look at him, but focus on the light, i see the yellow for the other street and i get set. As our light turns green i'm at like 5,000 rpm, i pop the clutch in perfect condition and my tires squeel as i lurch ahead..... the guy is right off my left rear and i'm thinking, yeah!!!! look at you now! gettin your arse handed to you by an old tired 240z!!! Anyways i lay off the gas after about 200 meters and this dude just races by me, probably all pissed off:) I pull into my favorite bar and have a drink on my old beat up foam fillez 240z:)

Tony...

[Zed]

There are baiscally two types of foam you discribe.

"Closed Cell" used in body shops around the world and the cheaper "open cell."

"Open cell" will attrack and hold moisture and cause more damage (corrosion) than it's worth.

I hope you got the right kind.

[St.stephen]

I had to read your post 3 times to be sure I was understanding what I was reading.

As much as I am an advocate of saving every Z, I am a huge advocate of doing it right. Do yourself a favor and take some time to fix the car the right way before that things folds up like a recliner.

Granted if you want to use cheap, backyard methods to fix your rust that's fine.....Cheap backyard methods to fix STRUCTURAL damage will earn you a view out of a hospital window.

Frame rail and floor pan kits are readily available and if you cannot install them yourself there are a plethora of places that would fix the car correctly. The major purpose being safety, not to mention preservation of your ride.

[EScanlon]

Tony:

While you no doubt have earned an honorable mention in the Macguyver School of Automotive Repairs, you need to read what everyone is telling you here.

I've no doubt that you have effected a "repair" that will maintain the pieces of the car together, and for the most part appear to hold them as they should be. The problem is that there is a strong possibility that your bolted on pieces of metal will tear through whatever amount of metal you have left just when you need it to be strong. Such as in braking, or effecting a turn at high speed, or during acceleration.

This in and of itself is something to be careful off, but when you post that you then went and started racing other cars with it.....

Well, maybe your intent is to be mentioned in the Darwin Awards.

Or this is a lame attempt at getting everyone all worked up over it?

[ZcarsRock]

Ok ya caught me!!! here is the skinny on me.

I am an 22 year Army Aviator(Instructor pilot/safety officer) I am fully aware of what some people(crew chiefs) are doing here to keep their cars going. I do actually have a 1972 240z. However what i indicated i have done are actual things some of the younger guys in my unit have done that landed them on the police blotter report or in the hospital. I have a wife of 20 years and 3 wonderful children. I am actually a very conservative guy(probably why i am still alive after 2 combat tours and 6200 flight hours in the UH-60 Black Hawk!) Anyway i love you guys and i use some of your postings to make safety points to my unit.

Thanks all

CW4 Tony Shultz

ZcarsRock, and so do Black Hawks!!!!

[2-77zs]

I've fallin out of a few of your birds. Spent almost 8 active years as a Scout/ Spec. Ops. 19d, 18d, 15e

I'm new to this site, but it seems like you made a few people nervous with your "go getter fixer upper " idea. Didn't sound like something a Cheif would do.

Anywho, are you still crashin those things, or retired?

[smg1404]

Hey 76 don't confuse us with reality!