It's like the more I do the more problems I run into. I am attaching pictures of the rails on the passenger side. They look pretty bad. What do I do now? Are there replacements? How do I replace? Is there another fix? It just keeps growing. Drivers side is better. But does have rust in it also. Thanks for your help.

Are you going for original restoration, or structuraly sound?

I am going for structuraly sound.

Thats relativly easy, first buy all the replacement components you can find. Second cut out all the really horrid rust and onestep the rest. fit up the replacement stuff and fill in the blanks with self fabricated pieces. Search the threads herein, you'll find lots of helpfull info in the body and paint section. It really looks worse than it is, but you will need some good welding skills to do it right.

JIMMY

I echo 5 HORSE'S input. I'm currently working on Project 3/72 that has the same issues. I will post some pics of the sections I have cutaway this weekend. The outside surface of the panel beneath the door frame will need to be stripped of all the rust. I am doing my own sandblasting and to be honest there is no other way to remove the rust from this portion of the lower valance thoroughly. It simply has too many curves and contours to get an abrasive wheel on effectively. You might as well plan to cut away the outer section of the valance so you can have the cavity stripped well or you will be doing it again in a year(or less). Several companies stock the replacement valance but try to find one that has the thickest gauge possible. Rust is caused in this area due to poor weather srips probably installed by the factory and never replaced until the owner notices rust. But the good news is IT CAN BE FIXED. If you remove the weather strip around the door frame(which I strongly suggest) you more than likely will uncover more cancer. Don't get discouraged. This is a chance to take care of it forever.

Thanks for the info, can you give me some sources for the parts I need. I Think I saw something about Tabco? but do they make everything I need? and if not, what are some other sources?

For everybody out there that thinks their Z has more rust damage than any other car out there, check out what these guys took on.

http://forums.hybridz.org/index.php/topic/41372-1971-datsun-240z-restoproject-vidspics/

I had a 68 R/T Charger in the days of film cameras that was worse than this car. I welded in brake metal angles everywhere it made sense and used sheet aluminum to replace the trunk, floor pan, fire wall and basically all internal panels. I let a real body man tackle the quarters and rockers. Back then you could get away with your wallet at a body shop, not any more. I recently got a quote to paint my 240 and almost pooped my paints. Don't look now, but we are going to have to use latex to paint cars in the near future, courtesy of our dear friends at the EPA.............F#*@ERS..............

BTW, I've had luck with using the onestep prior to sand blasting in those hard to reach areas. It converts the rust, so if you miss a small spot, the rust is already abaited.

Edited February 13, 201114 yr by 5thhorsemann

FYI this is the blaster I picked up a couple of years ago. It runs heavy on the air but is a solid tool in general.m And you cant beat the price. http://www.harborfreight.com/garage-shop/abrasive-blasters/40-lb-pressurized-abrasive-blaster-34202.html