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carotman
03-28-2008, 02:51 PM
Well, I decided to give myself a kick in the butt yesterday and decided to take care of the rust problem on my 1987 Hatchback S. It's been winter driven from 1987 to 2007, 20 years of northeast road salt! The good thing is that it's been rustproofed every year, this is probably what saved this vehicule.

I decided to start with the floor. Once it's nice and pretty again, the rest is easier to work on since it's outside the car thus making less of a mess. I was able to remove the car quite easily in the front but the back is a little more painful. I might try dry ice in the future.

Here's what it looked like when I removed the front left carpet.

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5451.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5451.JPG)

A close-up look shows you that it started to rust around the rubber plug
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5452.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5452.JPG)

The rear is definitely better, only showing minimal rust.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5453.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5453.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5460.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5460.JPG)

With the tar out of the way, you can really see the damage extent. It rusted around the plugs and spread a little further.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5454.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5454.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5459.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5459.JPG)

Close-up view on the biggest hole.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5455.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5455.JPG)

Here's the right side. There was a water lea there but I think it only started recently because the damage would have been alot worse.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5456.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5456.JPG)

Once again, it started to rust around the rubber plugs
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5457.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5457.JPG)

Cleaned!
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5458.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5458.JPG)

carotman
03-28-2008, 02:52 PM
The back right side is a little more rusted than the left side but nothing major.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5461.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5461.JPG)

More rusted rubber plugs under the rear seat. I'll have to remove the fuel tank to do a clean job on those. I'll do these later
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5462.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5462.JPG)

Today, I removed the dashboard and decided to check the source of the right side water leak. I removed the rain tray to see where it was rusted.

I poked everywhere with a flathead screwdriver and was left with this big hole!
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5463.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5463.JPG)

The left side is better so I'll be able to use this one as a template
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5464.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5464.JPG)

I'll have to remove the hood and both front fenders to do a clean job there. I expect to see a more rust that will need to be taken care of.

BITESIZE
03-28-2008, 02:55 PM
I shipped your hatchback trim today via ups. The package was too long for the post office to take it.

2oodoor
03-28-2008, 04:07 PM
I didn't know you had a hatchie too, so that is how many Accords now?? lol
What are you going to use to fix those holes?

carotman
03-28-2008, 04:19 PM
I didn't know you had a hatchie too, so that is how many Accords now?? lol
What are you going to use to fix those holes?

Yeah, I have an hatch also now. This makes 2 Accords + 1 parts car :D. I also have a Civic as a daily driver.

I'll use new sheet metal and weld it with my MIG. I'll then use POR15 to seal the surface permanently.

AccordB20A
03-28-2008, 06:48 PM
cool. and the rust isnt too bad

RamThis
04-05-2008, 08:37 PM
Wow, for around here that's a rust bucket and I wouldnt have even touched it with a 10 foot pole. Glad I dont live anywhere that has to salt the roads. My 3G doesnt have a spot of rust on it anywhere thank God. If I found what you found in my car, I would have quietly layed the carpet back down, rolled it outside, and put a "for sale" sign in the window...... As is, no returns or warranty!!! :lol:

Dr_Snooz
04-05-2008, 09:14 PM
Wow, for around here that's a rust bucket and I wouldnt have even touched it with a 10 foot pole. Glad I dont live anywhere that has to salt the roads. My 3G doesnt have a spot of rust on it anywhere thank God. If I found what you found in my car, I would have quietly layed the carpet back down, rolled it outside, and put a "for sale" sign in the window...... As is, no returns or warranty!!! :lol:

Ditto that. I can fix a lot, but haven't a clue what to do with rust. Looks like you do though.

Good luck with the project.

w261w261
04-06-2008, 03:34 AM
Good to get going on the floors before they get worse. In the '80's, I had a '67 Lincoln Continental convertible, the one with the 4 doors - the rears were suicide hinged. I was stepping out of it one day (with guests of course - the beast would hold 8 people in a pinch), stood up to get out (the top was down), and put my foot right through the floor down to the pavement, along with about a square foot of floor. Turns out the only thing holding it together down there was the thick application of undercoating. Very embarrassing. But instead of fixing it properly, I cut a piece of plexiglas and shoved it under the carpet. I sold the car a little later for one that wasn't so rust-challenged.

carotman
04-06-2008, 08:02 AM
That amount of rust isn't unusual around here. In fact it should have more :D

Most 10+ year old car has rust around here. 3rd gens are close to non existent, even in junkyards.

The key with rust repair is to replace the rotten metal with new one. You just have to take your time.

I'll take more pictures of the process soon. Right now, I'm almost done with cutting the rusted parts. Rust tends to form between joints and spreads where you can't see it until it's too late.

The die grinder and MIG welder are my best friends these days

BITESIZE
04-06-2008, 03:13 PM
Did you get the trim yet?

carotman
04-07-2008, 06:08 AM
The trim came in this morning :D

Thanks! They're in a very good shape compared to mine. I'll take a picture or two to show you these things can actually rust!

thegreatdane
04-07-2008, 06:30 AM
Looks like that should keep you occupied for a while! :) No wonder it was leaking in water! lol
Cant wait to see you getting started welding on it. Are you going to fix it up good, or just prevent it from falling apart?

BITESIZE
04-07-2008, 06:47 AM
The trim came in this morning :D

Thanks! They're in a very good shape compared to mine. I'll take a picture or two to show you these things can actually rust!

I actually looked around everywhere trying to find those awesome condition trim pieces for when I was going to paint my car, but I'm glad they went to a good home. Did you like the pepsi packaging? lol , you know me and pepsi! :cheers:

carotman
04-07-2008, 10:51 AM
thegreatdane: I'll fix it for good. Weld new metal and prep it for paint. This will sure keep me busy since I have 2 other cars to take care of. This hatchback is just a side project and I'm taking my time, not rushing anything.

BITESIZE: Yeah, I laughed when I saw the Pepsi can package. It help up well!

carotman
04-11-2008, 02:45 PM
I removed the windshield yesterday using this tool

http://www.northerntool.com/images/product/images/117357_lg.jpg

I had to ask a friend to help me. The urethane is very hard and I had to pull with both of my hands while my friend kept the tool aligned.

The rust isn't too bad on the pinch weld and will be easily repairable

I'll take pictures soon of course.

BITESIZE
04-11-2008, 02:48 PM
Pictures now!

2oodoor
04-11-2008, 02:51 PM
wow it has been awhile since I saw one of those knifes, I have one somewhere around here. If you can get in and out good in between the glass you can use a butane torch to heat up the blade every foot or so.

thegreatdane
04-12-2008, 11:47 AM
Good to hear the rust didnt get you. It can be a nasty sight when you remove a windshield sometimes.

carotman
06-19-2008, 05:09 PM
Not much has been going on in this project. I've been busy with tons of other things.

Anyway, I managed to remove most body panels and cut the rusted metal.

I need to do some sandblast now.

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5597.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5597.JPG)
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5598.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5598.JPG)
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5599.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5599.JPG)

This is sure taking longer than expected

BITESIZE
06-19-2008, 05:31 PM
Looks like alot of worky!

lostforawhile
06-19-2008, 06:19 PM
i had a small amount of rust around the back of my car under the bumper from improperly fixed accident damage. sandblasted it out.i had to a lot of repairs on that piece that goes under the lights,it came from a junkyard car that must have been in the north,couldn't find one decent so i had to rebuild that piece. check the rubber bumpers attached to your hatch door,i guarantee the metal pieces they attach to are rusted out. they are really easy to replace,they look like they have solid welds holding them to the hatch door,but thats seam sealer not welds, they are just spot welded on there. drill out the spot welds and they pop right off. there is solid metal underneath. they are welded to the surface. also drill a hole in each rubber bumper so water can drain,water gets trapped in there and collects,rusting them from inside.

carotman
06-20-2008, 03:03 AM
Yes, I'm starting from the front and slowly moving to the back of the car. I've seen them rust out on other cars. I really wonder what I'll find when I remove all the trim pieces and bumper in the back.

I just need some spare time now. I've got to finish at least the front of the car in order to repair some rust on my daily driver. I'll use the Hatch meanwhile.

carotman
08-08-2008, 04:19 AM
Well, I had some spare time this week and continued the project... I'll post pictures later but you guys will freak out when you see them.

I need a new rocker panel on both sides :D

Anyone knows where to get an aftermarket one? I tried NAPA but they don't carry them anyomre for our cars.

AccordB20A
08-09-2008, 11:45 PM
waiting for pics:::

markmdz89hatch
08-11-2008, 11:44 AM
Good luck with finding the rockers carot. How much of each side do you need? ...please don't tell me you need the whole damn thing on both sides.

Curious, what did you use to remove the tar mats on the inside floor?

If you need any hatch parts (except sheet metal), let me know. I have a bunch of spare parts tucked away in my garage, and should have access to a few hatch's for parts too. (Sheet metal is tough here too due to that same cancer.)

I take it that's going laurel blue too?

carotman
08-11-2008, 01:04 PM
I used a heat gun and a scrapper. Didn't take too long but sure took some time.

I would need the entire rocker panel to make a good perfect job. I may end up just patching it but that depends on how the replacement rocker looks. I found one at www.rustrepair.com for a decent price.

The car will remain Montreal Blue (B37M) as I like to keep the stock colors on cars :D

I will need some hatch parts in the future, Have you got any blue interior parts?

Now the pics:

Here's the windshield corner after I removed all the rotten metal. There is surface rust that needed to be sandblasted.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5599.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5599.JPG)

Here's the corner after a sandblast session and some POR-15 Metal Ready applied to it. (that's what makes the brown color)
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5601.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5601.JPG)

One sheet of the pinch weld has been redone here:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5602.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5602.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5605.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5605.JPG)

Now it's done and painted with POR15
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5716.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5716.JPG)

The other side wasn't as bad but I had to re weld some metal here too
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5700.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5700.JPG)

I had to reweld some metal here too. I don't have a "before" picture but it was a big rust hole before I started
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5701.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5701.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5702.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5702.JPG)

This is the worst part of the rocker panel. The jack point is still strong so it's only sheet metal that needs to be redone. Notice the thick road grime/dirt/anti-rust that's stuck in the fender well.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5703.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5703.JPG)

carotman
08-11-2008, 01:04 PM
Here's a picture of what the rocker panel looks like after I enlarged some holes where the rust had gone through.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5704.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5704.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5707.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5707.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5709.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5709.JPG)

Now, I discovered new holes after I removed all the stuff that was stuck to the fender well. I put all this grime in a bucket and it must weigh like 25 pounds!!! I'll take a picture of this later
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5710.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5710.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5711.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5711.JPG)

Side bumper mount is gone.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5712.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5712.JPG)

This is where the lower rear sub frame bolts to. Fortunately, this is only surface rust that will be all gone when I sandblast it.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5713.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5713.JPG)

Finally, this is the inside of the rocker panel
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5714.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5714.JPG)

This isn't quite a big deal to repair but will take some time.

A18A
08-11-2008, 01:56 PM
geezus that's ass :O

AccordB20A
08-11-2008, 02:12 PM
damn rust sucks

Tomisimo
08-11-2008, 04:15 PM
Holy Comoly this is rusted
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5704.JPG

I thought I had rust, but Yours take the cake! But I can assure you that if you have proper rockers that is prefited, that needs to be cut to fit it isint so hard as it seems. Ive done this on my car, just took me 10 days to do

http://i91.photobucket.com/albums/k313/Tomisimo/My%20Honda/Body%20Work/DSCN7723.jpg

good lock Carot

thegreatdane
08-13-2008, 08:29 AM
Oh dear!.. She's not looking so good no more. Still up to the task of fixing her?

87roach
08-13-2008, 08:44 AM
Keep up the good work, you have definetly got your work cut out for you.

EX-ileAccord
08-13-2008, 09:18 AM
thats nohing compaired to my 2 lol. I'm going to start the 4dr as soon as I can walk again. keep up the good work man, it will be worth it when its done.

Civic Accord Honda
08-13-2008, 09:40 AM
Gd!

Hauntd ca3
08-13-2008, 11:29 AM
looks like fun carot
dont you just love what road salt does to cars

AccordB20A
08-13-2008, 12:30 PM
glad that the roads over here dont have that shaZ on them. Cars rust enough up here without more additive no it.

Hauntd ca3
08-13-2008, 01:44 PM
maybe in the north island mate:)

carotman
09-16-2008, 05:15 AM
I was wondering if someone has a parts car with the side bumper mount in good condition?
(this part)
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5712.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5712.JPG)

It would be easier for me to just weld a piece from a donor car than try and fabricate a new one. Most of the cars here are rusted beyond repair so this part is one of the firsts to go.

I would need both sides.

2oodoor
09-16-2008, 06:52 AM
deleted

thegreatdane
09-16-2008, 08:05 AM
If you buy a wheel arch patch panel you get a part that covers the lager area marked with yellow in my picture here, and "all" you have to do is reconstruct the inside part:


http://img227.imageshack.us/img227/250/imgp1097ce8.th.jpg (http://img227.imageshack.us/my.php?image=imgp1097ce8.jpg)

carotman
09-16-2008, 08:21 AM
I have a replacement wheel arch for a sedan here and it doesn't have that piece where the bumper attaches to.

The arch itself on the hatchback isn't in that bad to my surprise. I just need to weld a few bits here and there.

OldSkoolA20accord
09-16-2008, 01:59 PM
this car wouldnt be the one i saw on ebay a few weeks ago would it? i saw one that was the same color, hatch back, with a shit load of rust.

carotman
09-16-2008, 03:03 PM
LOL,

Nope, I got this car 2 years ago.

OldSkoolA20accord
09-16-2008, 03:11 PM
that car i found on there had rust from hell. its like if you hit a bump hard enough it would rip apart. lol

carotman
12-11-2008, 12:26 PM
I just ordered a RH rocker panel and wheel arch from www.rustrepair.com.
Costs 92.95 + shipping.

I have a full MIG wire spool and full Argoshield tank

I hope I'll have enough spare time this winter to work on it. Sandblasting makes such a mess but in the end, it till be worth it.

86ccord
12-11-2008, 07:16 PM
looking good man.. keep it up!

carotman
12-16-2008, 03:42 PM
Tabarnac!!

The rocker panel isn't available anymore from these guys (www.rustrepair.com)

It was "available" until I made an order. I'm sure the left side rocker panel will meet the same fate.

Anyone knows where to get those besides the dealer?

I might just order the real thing from the dealer but it's like 175 bucks a piece... I'm sure it costs double that in Canada and our currency got wayyyy down from what it was this summer.

Hauntd ca3
12-17-2008, 12:52 AM
by rocker panel do you mean the sills.
the long curved bit that runs from the front to rear wheel arch.
if it is what im thinkin, a decent sheetmetal place could make you one.
just show them what you want and they'll be able to bend it or better still make a template or cut a section out with out ruining it

carotman
12-19-2008, 03:01 PM
Well, I ordered one from the dealer... costa 135 bucks at my price. Not too bad and it's the right part.

Low_Rida
12-19-2008, 03:40 PM
Well, I ordered one from the dealer... costa 135 bucks at my price. Not too bad and it's the right part.

I need 2 rocker panels for my coupe, i was gonna curve some sheet metal, bolt it on and fiberglass and paint over it. is this a bad idea?

carotman
12-19-2008, 03:53 PM
Not at all.

It depends what you want to do with the car in the future.

Low_Rida
12-20-2008, 06:22 AM
Not at all.

It depends what you want to do with the car in the future.

Thanks, yeah thats true, i dont care for perfection, i want more "go" than "show" but i do love the looks of the 3gee, they are quite sexy.

carotman
12-22-2008, 07:13 AM
I sent an Email to a Honda dealer in the US. I may buy a new floor pan but it's discontinued and not available anymore in Canada.

If any of you guys plan to get rid of an hatch, think about all these parts I need :D

thegreatdane
12-22-2008, 07:25 AM
mmmmmmm, oem body parts, drool!

A new floor pan?? :jaw: Maybe you should ask for a new complete body instead lol :)

How poor condition is the floorpan in? Any pics of the illness?

"Tabarnac!!"?? is that french for "goddamn it all to hell" lol

carotman
12-22-2008, 08:29 AM
Hahaha, the floor is damaged around those rubber plugs. I'll have to weld some metal there. You can see the pictures on page 1.

I was planning to repair the floor but it might be even more time consuming than just put a new floor board and forget about it. Wel'll see if I can get my hands on one and how much it costs.

I think you figured "Tabarnac" pretty well. If you watched the movie "Love Guru" you know what it means :D

carotman
01-18-2009, 10:22 AM
I received the brand new Honda rocker panel this week. It's all pretty and accurate (yeah)

Now I wonder what's the best way to install it. Should I cut the whole thing on the car and install the new rocker panel or should I just cut the minimum amount of sheetmetal on the car and march the replacement panel to what I cut?

I think welding the new rocker panel as a whole would be easier and lead to less welds. The thing is spot welded on the bottom and door sill. The biggest welding job would be on below the rear molding and where the door hinges are.

Anyway, I got some rust repair job to do behind the rocker panel itself. It was really cold here this week (like -30C) so I couldn't do anything on the car.

thegreatdane
01-18-2009, 11:21 AM
I received the brand new Honda rocker panel this week. It's all pretty and accurate (yeah)

Now I wonder what's the best way to install it. Should I cut the whole thing on the car and install the new rocker panel or should I just cut the minimum amount of sheetmetal on the car and march the replacement panel to what I cut?

I think welding the new rocker panel as a whole would be easier and lead to less welds. The thing is spot welded on the bottom and door sill. The biggest welding job would be on below the rear molding and where the door hinges are.

Anyway, I got some rust repair job to do behind the rocker panel itself. It was really cold here this week (like -30C) so I couldn't do anything on the car.

Things can get really nasty behind those rocker panels.
Definately weld the panel in as a whole. It is much much much easier.
But you might want to cut down the size on that bit covering the door pillar and part of the rear quarter panel incase the panel ever need to be replaced again. That way there will still be fresh metal to weld in next time.
I think a picture update would be in order :D
Any luck with the floorpan?
Btw I did actually watch Love Guru, I remember now :)

carotman
01-21-2009, 09:32 AM
I got the wheel arch today.

Now, if only it could warm up a bit here...

2ndGenGuy
01-21-2009, 10:23 AM
Quite the project you've got here! I thought the temps were bad where I was, but -30C is ridiculous! I better take more advantage of our relatively mild weather.

b20a86lude
01-23-2009, 06:35 PM
wow im hAVING A HARD TIME FINDING A NEW DRIVER QUARTER FOR MY LUDE AND OTHER STUFF

carotman
02-06-2009, 05:07 PM
Here's the rocker panel I got from Honda. It's a perfect fit

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5990.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5990.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/CIMG5991.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/CIMG5991.JPG)

Not much progress. I've been lazy a bit, it's cold outside and I need money to buy other stuff before the project can continue.

87roach
02-08-2009, 08:31 AM
It'll be nice to see those new rockers on there! I know what you mean about the cold.. and the money..

b20a86lude
02-16-2009, 03:36 PM
ur pix are messed up

carotman
11-09-2009, 07:36 AM
Ok, I don't have pictures (yet) but I finished the cabin floor. There no more hole in there. I took off the fuel tank and I coated it with POR-15 so it should last for a long time.

The bad news is that I broke the rear brake lines. In fact, they broke when I touched them so they were really rusted. They rusted and snapped exactly where the rubber grommet it.

It turns out that these aren't available anymore from Honda in Canada. I might check in the US for new replacement or I could just make my own lines.

Civic Accord Honda
11-09-2009, 02:57 PM
sounds like a good time to do custom lines and do a brake line tuck ;)

thegreatdane
11-09-2009, 03:06 PM
No pics?? thats cruel! I love seing bodywork pics. Good job getting the floor done though!
Your rusted brake lines are no biggie. You can either cut the lines under the backseat, put a flare nut on them and flare them, put on a brake line connector and make a new short section of line going to the rear wheels. Downside is that the brake line connector looks ghetto if you plan on running the car with no backseat and it will be visible.
So if you plan on taking out the entire interior during your repairs and want the cleaner 1 piece brake line it's not difficult at all to make the entire brake line by hand.
So dont sweat it if you cant get the oem ones.
The bonus of making your own lines is that you can relocate or hide brake lines and you can select between stainless(bitch to work with though), copper and steel lines. Just make sure to get a good brake line bender to get clean factory looking bends.
Good thing you didnt step on your brakes while you were still driving the car or the pedal would have gone to the floor lol.
Now get pics dammit!

A18A
11-09-2009, 03:24 PM
that's scary knowing your brake lines are that bad, would hate to press the pedal then have fluid squirt out the back of your car and not having the car slow down much :O

No pics?? thats cruel! I love seing bodywork pics. blah blah blah. Now get pics dammit!

and i agree :D

carotman
11-11-2009, 07:02 AM
Ok

Here are some crappy cell phone pictures of the repaired floor. I tried to keep as much as the original floor shape as I could. I sandblasted everything and coated it in POR-15. It should last a long time.

Diver floor:
http://carotman.no-ip.com:8888/album/rwx_gallery/repaired_driver_floor.jpg

Passenger floor.
http://carotman.no-ip.com:8888/album/rwx_gallery/repaired_passenger_floor_1.jpg
http://carotman.no-ip.com:8888/album/rwx_gallery/repaired_passenger_floor_2.jpg

Now, I took the fuel tank off to repair what's damaged under it. As sandblasting makes a LOT of mess, I still wanted to be able to take the car in and out of the garage.

The problem is that my driveway is in gravel and has a slight slope. I can take the car out but can't puch it back in without 2 people helping me.

I just thought I'd make a temporary fuel supply of some sort. I decided that my Tecumseh snowthrower tank was the best candidate!

http://carotman.no-ip.com:8888/album/rwx_gallery/ghetto_fuel_tank_1.jpg
http://carotman.no-ip.com:8888/album/rwx_gallery/ghetto_fuel_tank_2.jpg

Since carbs don't actually need fuel pressure, this works like a champ!

I'll take some pictures of the subframe damage near the fuel tank.

Hazwan
11-11-2009, 07:47 AM
Hahahaha nice tank lol

thegreatdane
11-22-2009, 06:02 AM
Looks good! What about the subframe is it rusted away completely or is it still in okay shape?

A18A
11-22-2009, 03:40 PM
looks fun driving it without a seat :P but that does look good though :thumbup:

Tomisimo
12-02-2009, 08:46 AM
Nice to see he project coming along, did you changed rockers yet? And props on floor work, I need to lift my carpet and see, I discovered that drain hose from moonroof came loose on the drivers side, so it siped inside, I fix that but I dont know how long it was draining inside.. Hope and pray its ok..

carotman
12-17-2009, 12:52 PM
Here are new pictures I took today.

I've been working on the project this week. I mainly removed the rear knuckles/subframe to clean everything and get ready for the sandblast session.

There's so much dirt/mud/crud stuck under this car it's absolutely insane. I use WD-40 to clean all this mess. It's the only stuff that really does something.

Here are some pictures:

Rear knuckles and sway bar.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/rear_knuckles.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/rear_knuckles.jpg)

You can see here what I meant by crud
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_crud.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_crud.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_crud.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_crud.jpg)

This is the stuff that's under the car:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/rear_crud.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/rear_crud.jpg)

Now, I had to clean the strut tower for further inspection. It turns out this is only minimal surface rust
Left:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_strut_tower.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_strut_tower.jpg)
Right:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_strut_tower.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_strut_tower.jpg)

The wheel wells aren't pretty, especially the left side. Nothing my Lincoln Electric can't fix.
Left:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_wheel_well.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_wheel_well.jpg)
Right
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_wheel_well.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_wheel_well.jpg)

A hole developed under the rear bumper on both sides. This is the worst one:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/under_bumper.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/under_bumper.jpg)

carotman
12-17-2009, 12:52 PM
Here's what my cleaning job looks like. I don't have "before" picture but I'm sure you can imagine how it was:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/no_fueltank.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/no_fueltank.jpg)

Now the uglier part :( The attachment points or the rear crossmember. The right side is really rusted. Fortunately, this is all fixable, thanks to my Lincoln again.

Left side:

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_subframe_1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_subframe_1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_subframe_2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_subframe_2.jpg)

Right side:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_subframe_1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_subframe_1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_subframe_2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_subframe_2.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_subframe_3.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_subframe_3.jpg)

As you can see, there's a hole where there shouldn't be one. I'll sandblast this, patch this up and add another layer of metal all around this. I have an SE-i spare car that I could take this part from but I'm not sure if it's in good condition on the other car. I'll have to investigate this one.

markmdz89hatch
12-17-2009, 01:03 PM
and why don't you just get a hatch from down south in the US?

I admire your work and dedication here. I have to admit I'd be pretty close to throwing in the towel if I had something so bad as a core to work from. But props to you (again) for keeping this one from a certain junkheap.

carotman
12-17-2009, 01:09 PM
Bah, When I'll be finished with this one it will look brand new. If I got a hatch from down south, I'll probably have to work on it too anyway to fix some things.

Isn't the fun part about cars is working on them? :D Plus, the experience I get from this is priceless (just like the Visa ads hehe)

The only thing that scares me a bit is the outside wheel arches. I'll have to made extra caution not to warp the metal when welding.

Did I mention I want to rebuild the stock carb? Yeah, I know I'm crazy!

markmdz89hatch
12-17-2009, 01:42 PM
Bah, When I'll be finished with this one it will look brand new. If I got a hatch from down south, I'll probably have to work on it too anyway to fix some things.

Isn't the fun part about cars is working on them? :D Plus, the experience I get from this is priceless (just like the Visa ads hehe)

The only thing that scares me a bit is the outside wheel arches. I'll have to made extra caution not to warp the metal when welding.

Did I mention I want to rebuild the stock carb? Yeah, I know I'm crazy!

Rebuilding the carb is the easiest part of this whole project you got going on.

If you want, i have a spare carb i'll send you for free to tinker with. It's of no use to me anymore. :ugh:

carotman
12-17-2009, 02:34 PM
I wish I could use your carb but the Canadian 86-87 carb is different than the rest of what you guys got. There's no O2 sensor on the manifold and the carb lacks the A B C ports tp change the mixture.

I have a spare carb to work on anyway.

Can you beleive I drove this car to Wildowwd 3 years ago? :D It was it's last trip before the overhaul.

thegreatdane
12-17-2009, 02:38 PM
wait, are you saying that you've cleaned that whole area of the subframe using only WD40?
From an aerosol can? And didn't that require a ridiculously large amount of WD40? I didnt think you could clean stuff like that with WD40.
Whatever you've done looks like it's done a good job.

Doesn't look too bad though. I was expecting to see all the crossmembers rusted through. I've had a couple of 3gees whose subframe would make yours look the mintiest ever lol.

Btw. a little word of advice I should have given myself when I started on my Aerodeck, you might as well strip everything off the car from the beginning as you'll probably end up removing all of it bit by bit down the road anyway. It makes working on the car easier not having to dodge things (like that exhaust you've got hanging there) all the time. And you wont have to worry about destroying interior pieces or making them dirty and stuff like that.

carotman
12-17-2009, 04:37 PM
Haha no, it's not in an aerosol can. I bought a 4L container and use a sprayer.

I know what you mean by taking everything apart. I've got most of the stuff out but I'm afraid I'll just have an empty shell in the end!

thegreatdane
12-18-2009, 03:14 AM
Sweet. They only sell the aerosol cans here though and they are expensive enough already.
I find it effective using WD40 to soak pieces like the hood hinges to clear out the rust from the joint where you cant get to otherwise.

hammer3rd
01-19-2010, 08:06 PM
Did you ever get the pieces for the rear suspension?

carotman
02-17-2010, 02:42 PM
I haven't worked on the car since... Winter blues they say.

The project isn't dead anyway.

I just got my hands on these:

Genuine JDM (OMG) Coupe/Aerodeck Window visors.

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/visor_1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/visor_1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/visor_2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/visor_2.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/visor_3.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/visor_3.jpg)

They fit pretty well and will look awesome once they're repolished with Meguiar's Plast-X

markmdz89hatch
02-17-2010, 02:44 PM
I feel very privileged to say I've seen this hatch in person... ...and the rust is really not as bad ::cough:: as it looks in the pics. Thanks again for the hospitality and show&tell on the JDM parts. ...dammit.

gtmst3
02-18-2010, 12:23 PM
i would like those visors for my new coupe

carotman
04-26-2010, 10:57 AM
I repaired the right side rear frame rust last week. Was a pain to do but it's now solid again.

I'll work on the left side in the comming weeks.

Sorry, no pictures yet (Yeah I know it's boring).

I'll take pictures when it's all repaired. I need to finish this ASAP so I can move the car out of the garage again.

carotman
07-19-2010, 06:02 PM
Ok, here are some updates on the project.

I managed to completely sandblast the fuel tank/subframe area and paint it with POR-15 (awesome stuff). I still need to apply seam sealer to the welds and joints.

Underside:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/no_fueltank_repaired1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/no_fueltank_repaired1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/no_fueltank_repaired2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/no_fueltank_repaired2.jpg)

Left sub frame section:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_subframe_repaired1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_subframe_repaired1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_subframe_repaired2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_subframe_repaired2.jpg)

Right sub frame section:

I had to weld some reinforcements there. It's now very solid and should be good for a long time now.
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_subframe_repaired1.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_subframe_repaired1.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_subframe_repaired2.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_subframe_repaired2.jpg)

Wheel wells:
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/left_wheelwell_repaired.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/left_wheelwell_repaired.jpg)http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/right_wheelwell_repaired.jpg (http://carotman.no-ip.com:8888/album/rwx_gallery/right_wheelwell_repaired.jpg)

No more rust! In this area at least.

import racer
07-20-2010, 04:38 PM
Hey Carotman I don't know about where you're at but in Nova Scotia you can't run copper brake lines.

carotman
07-20-2010, 05:24 PM
I plan to buy a brake line loom at Napa or something and make a new one. I DID find one in the states tough but it's 80 bucks plus shipping... I'm an OEM parts freak but 80 bucks for a single line is a bit expensive.

Civic Accord Honda
07-26-2010, 12:56 AM
damn your putting alot of work in to it ^_^ theses are the kinda of threads i like to see!

carotman
09-01-2010, 09:17 AM
Oh

The car is back on it's wheels, brake lines are completely redone.

Next step is the rocker panels.

I got a zinc plating kit too. It's just awesome :D

HERBERT
10-13-2010, 01:47 PM
Did this ever get finished????

Xaisk
10-13-2010, 03:18 PM
Thats amazing.. The snowblower tank as a temporary fuel tank. Man thats great. :jaw:

gp02a0083
10-13-2010, 03:58 PM
Oh

The car is back on it's wheels, brake lines are completely redone.

Next step is the rocker panels.

I got a zinc plating kit too. It's just awesome :D


nice , what does the kit consist of?

carotman
10-14-2010, 10:28 AM
The project is still rolling. I've been lazy and I keep postponing stuff. I've been busy at work too. :(

I should finish the lower panels before winter kicks in. This project is taking wayy too long to complete. Once the unibody is finished, the rest will be a piece of cake.

The Zinc kit if from caswell plating
http://www.caswellplating.com/kits/zinc.htm

I bought the 3 gallon kit.

import racer
10-14-2010, 04:11 PM
Hey Carotman,where did you buy the por-15.I've heard of it before but have not been able to find it anywhere.

carotman
04-05-2012, 12:06 PM
I got these yesterday:

http://www.ebay.com/itm/120886812257?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

It will serve as a power window conversion on my hatch :D

obdriver6
04-05-2012, 01:43 PM
WOW! You sure are dedicated to this project, keep it up!

A18A
04-05-2012, 03:33 PM
Do you plan on making it looks OEM?

carotman
04-07-2012, 07:56 PM
Do you plan on making it looks OEM?
Of course!

It was an OEM option for the Civic so it should look OEM anyway :D

FresnoCA5
04-07-2012, 08:32 PM
i didn't read the whole thing, but did you go with the POR15? eastwood makes a few products that kick that stuff's butt. just some info, in case you haven't checked it out yet. it seals MUCH better and protects better x 1,000,000.

carotman
04-07-2012, 08:37 PM
I did use some POR15 but the project isn't finished yet.

What's the Eastwood product you're talking about?

Burn1nRubb3r
05-16-2012, 08:34 PM
Is it possible I could get the source of were you got those rocker panels? I can only find rocker panels for sedans....

FresnoCA5
05-17-2012, 04:44 PM
I did use some POR15 but the project isn't finished yet.

What's the Eastwood product you're talking about?

go to Eastwood.com

their stuff is amazing. they have one product that you spray on rust to neutralize it, then another to seal it off. you can roll on, brush on, or they have foams for inside of frames, etc. awesome stuff. check it out.

89HatchbackLxi
05-20-2012, 01:42 PM
go to Eastwood.com

their stuff is amazing. they have one product that you spray on rust to neutralize it, then another to seal it off. you can roll on, brush on, or they have foams for inside of frames, etc. awesome stuff. check it out.

I saw that a few months ago. It looked pretty good from what they were showing in the video, however that was just an ad, so I guess that is kinda expected. Have you tried the stuff, and if you did, did it work like they say it does?

carotman
05-23-2012, 03:42 PM
Is it possible I could get the source of were you got those rocker panels? I can only find rocker panels for sedans....
I got them at the dealer directly!

2oodoor
05-27-2012, 01:58 PM
Keeping it alive, great project... Lucky find on the visors im jealous :o)

carotman
12-11-2012, 08:08 PM
I started to work on the car again.

I gave myself a kick in the butt and decided that I have to work on the car every day. Even if I just remove 1 bolt or grind a square inch of rust, it counts. I'll be able to finish this project by working on this project in little increments. I've been delaying the project for more than a year. If I had done this before, this car would be completed by now...

So far, I almost too out the rocker panel this week. Of course. I'll take pictures when it's completely removed.

A18A
12-12-2012, 12:06 AM
I have to work on the car every day. Even if I just remove 1 bolt or grind a square inch of rust, it counts.

that's good thinking! I should do the same.

carotman
12-13-2012, 07:15 PM
Finally took the thing off tonight! It went faster than I first thought it would. You can clearly see the reason I had to take that off... rust cancer! The front part isn't really a problem but the rear will be a fun challenge.

http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0183.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0183.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0184.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0184.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0185.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0185.JPG)
http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0186.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0186.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0187.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0187.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0188.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0188.JPG) http://carotman.no-ip.com:8888/album/rwx_gallery/thumbs/IMG_0189.JPG (http://carotman.no-ip.com:8888/album/rwx_gallery/IMG_0189.JPG)

gp02a0083
12-14-2012, 09:01 AM
after you replace the rocker panel spray the inside of it with stuff called honey coat. I used to use that after my 1/4 panel and rocker panel repairs to give the inside some rust protection.

carotman
12-14-2012, 10:18 AM
Thanks for the input. I was wondering what would be best for long term rust protection. I'll use POR-15 for the paint but weld protection will probably that honey coat

gp02a0083
12-14-2012, 10:43 AM
being your taking your time and doing this the right way, i would put in that extra effort. Por-15 is a great product, many of the guys in the g-body and Oldsmobile community use the stuff religiously. I would also suggest getting a few cans of zinc weld through primer for when you re attach the rocker panel. then use the honey coat to finish it off when your done welding. I also found that using fire proof expanding foam will fill the rocker panel cavity to prevent further corrosion and stiffen's up the chassis a little bit. I did that to my gold hatchback and it made a bit of a difference, not to mention its light weight too.

steverine
07-28-2015, 01:33 PM
Hey Carotman - you still out there? Did you ever finish this project?
I have an 88 DX on which I am currently trying to fix rocker panels.

carotman
08-05-2015, 09:43 AM
Hi

It isn't finished. I had more important work to do elsewhere I guess. The project isn't dead and I plan to work on it soon.

MessyHonda
08-13-2015, 03:15 PM
Come on carotman! If it was not for your website back in 2002 I would of never known that accords could of been modded.