Hi guys,
Tomorrow I'm thinking about tackling the rust issues found in 02-03 x types. For those who don't know the front inner wheel well rusts out. Now for my question. How do I tell if this rust is structural or if it's just the metal for the wheel well, (it's not the wheel well that rust, I can't remember the area that rust, the name of it…) I know there's some sever rust there, but I don't' know if it's structural, anyway to tell? Also, I bought some POR 15, with some fiberglass webbing to rebuild anything that's rusted through, will this work??? (keep in mind that I don't have a welder to weld in patch panels)

Thanks guys for your help.

 

James, think of it this way and hopefully it will make things clearer. If the engine or the suspension bolts to it, then it is structural. So, on the front end of our cars, you are really looking at just the 2 arms that are attached to the firewall that stick straight out to the headlight area. MOst of the other stuff is just beautification metal to get the shape of the car. When you get to the passenger area, then things change slightly as pretty much everything on the main shell of the car is structural in some way, shape, or form.

 

X Types rust in the A pillar and sills due to an idiot design of the wind shield drain. These are structural and fatal.

 

Okay guys I took a look at both places. Around the drain it's rusted really bad, then going back into the A-frame it's rusted really bad. I fixed around the drain, put some webbing and some POR-15, followed by body filler, I'm worried about the A-frame really bad.
Is it possible to make a new A-frame and weld it in? What would be some of the problems associated with cutting out the rusted parts of the A-frame?

Thanks for the help guys.

 

I assume when you say A Frame you mean A Pillar?

You can get a sill panel but that's just a cosmetic fix. The A pillar and sill are made up of several layers and they all need to be there for strength. Also when you weld the new panel in the welds inside will rust immediately because they get wet every time there's water on the wind shield. It's not an easy place to rust proof either. No, it's a fatal flaw!

 

Hey Tony,
Yeah, I mean A Pillar, sorry.

Looks like I'm going to be working really hard to rust proof this thing!