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#1 2020-09-14 20:26:10

supremekizzle
Member
Registered: 2014-08-05
User Number: 20841
Posts: 50

I've got rot :( worth fixing? Pics inside...

Welp. I've got the dreaded strut rot. What are current opinions on fixing? Not as bad as some that I've seen, but not good... Any ideas as to cost? I'm in SE MN. Thanks. I really love this car and want to save her.

Album link: https://imgur.com/a/DxlKdRi


Tried to post the images in the thread, but it's not working.

https://i.imgur.com/E8uoykx.jpg
https://i.imgur.com/blU7uxg.jpg
https://i.imgur.com/1fDV1h2.jpg
https://i.imgur.com/92YqznL.jpg
https://i.imgur.com/lLuwMFs.jpg
https://i.imgur.com/8vvlB2p.jpg
https://i.imgur.com/AOF3ejr.jpg
https://i.imgur.com/UVNkXsf.jpg
https://i.imgur.com/BwFl7Gt.jpg
https://i.imgur.com/Gaxf3cR.jpg
https://i.imgur.com/cjnGvXV.jpg
https://i.imgur.com/iCWQCgW.jpg
https://i.imgur.com/Re5PPAt.jpg
https://i.imgur.com/jXslSdV.jpg
https://i.imgur.com/rkwP0Fh.jpg

Last edited by supremekizzle (2020-09-14 20:41:40)

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#2 2020-09-14 20:40:49

dotmaster206
Member
From: Denver, CO
Registered: 2012-03-10
User Number: 7123
Posts: 2110

Re: I've got rot :( worth fixing? Pics inside...

It's definitely fixable, yes. The holes at the base there are interesting - usually it's around the seat back catches since that's where the bolt passes through to the outside.

I believe most of the folks that have fixed this rust issue have either done it themselves or taken it to a custom 4x4 fab type place to get the rust cut out and new steel sheet welded in.

What's the rust like on the rest of the car? The front subframe, control arms (has the recall been done?), and body at the rear wheel corner where the door cutout is generally are all key locations that tend to rust first/worst. If you have a lot of rust in those places too, it may be not worth repairing - depends on how much you care about the car.

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#3 2020-09-14 20:46:39

supremekizzle
Member
Registered: 2014-08-05
User Number: 20841
Posts: 50

Re: I've got rot :( worth fixing? Pics inside...

dotmaster206 wrote:

It's definitely fixable, yes. The holes at the base there are interesting - usually it's around the seat back catches since that's where the bolt passes through to the outside.

I believe most of the folks that have fixed this rust issue have either done it themselves or taken it to a custom 4x4 fab type place to get the rust cut out and new steel sheet welded in.

What's the rust like on the rest of the car? The front subframe, control arms (has the recall been done?), and body at the rear wheel corner where the door cutout is generally are all key locations that tend to rust first/worst. If you have a lot of rust in those places too, it may be not worth repairing - depends on how much you care about the car.

Subframe isn't too too bad. Not completely rotted yet, but rusted for sure. Some at rear passenger quarter panel and gas tank. Not extreme yet, but needs fixing. I took the car to a saab place for control arms, but he said they weren't bad enough to be replaced and just coated them per the recall recommendation. I'm gonna try and get quotes tomorrow. Thanks for the response. Any ballpark on what others have paid for someone else to do it? I've never welded before.

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#4 2020-09-15 09:48:25

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 610

Re: I've got rot :( worth fixing? Pics inside...

Certainly fixable, could also be ignored for a few years before it becomes a structural issue. Do you ever want to sell the car or is it on the way out? I've fixed a few myself, I also paid a welder/fabricator in my area $500 for an afternoon of labor: I drove to his shop, pulled the struts, he plasma cut, fabricated patched, welded in, I applied seam sealer, primer, undercoat and put the car back together. Many of these guys are mobile, if you can find one to come to your house it would be easier as less rush to finish the job and put back together. Another good option are 4x4 shops, but many people hate working with rust. Collect some pictures of the job in progress to show them what you're expecting. It really is a pretty easy job apart from the thin OE metal, and it certainly doesn't have to look pretty.

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#5 2020-09-15 09:56:57

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 610

Re: I've got rot :( worth fixing? Pics inside...

Black car is the one I had done, silver car I did this year myself. Doesn't really matter how small the rot area is, go for a bigger patch as there will be more rust in between the layers lower down. Shop cat inspected the job afterwards so I'm confident it was a success.

https://imgur.com/szfJeVWh.jpg
https://i.imgur.com/xiha7HAh.jpg
https://i.imgur.com/HoY8Rihh.jpg

Last edited by snowphun (2020-09-15 09:58:51)

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#6 2020-09-15 11:39:34

jixaw
Member
From: Cambridge, MA
Registered: 2016-02-22
User Number: 35856
Posts: 184

Re: I've got rot :( worth fixing? Pics inside...

i wound up cutting and riveting and fiberglassing...it was a royal pain but not hard work... however, you might need a helper like Snowphun has pictured above


2005 Saab 9-2x Linear - Auto - Deep Blue Mica - Cold Weather Package - - Mods: Aero Rear Sway Bar, Perrin FSB, Whiteline QR RSB, KYB-G Excel Shocks, STI Pink Springs, Tsudo UEL, Custom catback with Magnaflow, Centric rotors & posi-quiet ceramic pads, 17" ASAs w/Dunlop Direzzas (summer), 16" OEM alloys w/studded Nokian hakka 7's (winter), 35% tint sides/rear

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#7 2020-09-15 15:18:49

supremekizzle
Member
Registered: 2014-08-05
User Number: 20841
Posts: 50

Re: I've got rot :( worth fixing? Pics inside...

snowphun wrote:

Certainly fixable, could also be ignored for a few years before it becomes a structural issue. Do you ever want to sell the car or is it on the way out? I've fixed a few myself, I also paid a welder/fabricator in my area $500 for an afternoon of labor: I drove to his shop, pulled the struts, he plasma cut, fabricated patched, welded in, I applied seam sealer, primer, undercoat and put the car back together. Many of these guys are mobile, if you can find one to come to your house it would be easier as less rush to finish the job and put back together. Another good option are 4x4 shops, but many people hate working with rust. Collect some pictures of the job in progress to show them what you're expecting. It really is a pretty easy job apart from the thin OE metal, and it certainly doesn't have to look pretty.

$500? That's actually a lot less than I was thinking. Of course, rates might be higher where I am, but I'd be good with $1,000 or under. I'm definitely keeping the car until dead. I'd prefer that to be later rather than now though....

snowphun wrote:

Black car is the one I had done, silver car I did this year myself. Doesn't really matter how small the rot area is, go for a bigger patch as there will be more rust in between the layers lower down. Shop cat inspected the job afterwards so I'm confident it was a success.

https://imgur.com/szfJeVWh.jpg
https://i.imgur.com/xiha7HAh.jpg
https://i.imgur.com/HoY8Rihh.jpg

That's some beautiful work. Wanna come out to MN and do mine? lol


jixaw wrote:

i wound up cutting and riveting and fiberglassing...it was a royal pain but not hard work... however, you might need a helper like Snowphun has pictured above

How are rivets holding up? I've never welded, so riveting may be more in my league. Any further rust issues? Or did you re-coat everything? Thanks

I went back to the car and starter beating and peeling away. It isn't too long until the metal starts tearing like regular sheet metal and not crumbling. Also, there's a really thick bent metal plate up in the strut tower on the outside and really thin metal on the inside. The thick metal has rust, but it seems structurally sound and isn't peeling at all. It's just the thin tuna can metal on the inside. I'm waiting on quotes, but I think I'm going to try and save her. Has anyone "injected" a rust converter in-between the two layers? Might buy some time?

Last edited by supremekizzle (2020-09-15 18:35:23)

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#8 2020-09-15 20:03:46

itsnotmeitsyou
Potato, Patreason...
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From: San Antonio, Texas
Registered: 2011-07-31
User Number: 5779
Posts: 2608

Re: I've got rot :( worth fixing? Pics inside...

I think shop cat is trying to point out that front bumper has a torn off lip.


2005 Saab 9-2x Aero:  More than you've had done to your car.
2015 Forester XT 'TS' clone

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#9 2020-09-16 09:15:21

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 610

Re: I've got rot :( worth fixing? Pics inside...

supremekizzle wrote:

$500? That's actually a lot less than I was thinking. Of course, rates might be higher where I am, but I'd be good with $1,000 or under. I'm definitely keeping the car until dead. I'd prefer that to be later rather than now though....

Keep in mind he did his skills, I took care of the mechanical stuff. Four hours of labor, a bit of scrap metal and some consumables, we both left happy. As I was repairing the silver car more than once I questioned why I was doing it myself, it's a relatively awkward space to work in. I found my guy by posting in a local FB "redneck buy/sell" group.

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#10 2020-09-16 09:15:51

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 610

Re: I've got rot :( worth fixing? Pics inside...

itsnotmeitsyou wrote:

I think shop cat is trying to point out that front bumper has a torn off lip.

He had a lot to say about the entire process.

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#11 2020-09-16 11:38:05

jixaw
Member
From: Cambridge, MA
Registered: 2016-02-22
User Number: 35856
Posts: 184

Re: I've got rot :( worth fixing? Pics inside...

so far the rivets are good....used over 100 of them though smile...

I took out all the interior and started just knocking rust out...mine was as bad as yours...cutting away the rust revealed large gaping holes...i had to remove the seat back bracket and remount it after the repair...

once the rust was out i riveted some aluminium sheet stock pieces to cover hte holes..i dont remember how thick the aluminium was but i got it at home depot...after it was all riveted, i coated everything with tiger hair fiberglass....i globbed it on good and pushed int cracks....basically just putting a good layer all over the aluminium and covering the rivets...

I can give you more detials if needed....it took me a couple of days to do and i had a buddy give me a hand.....


2005 Saab 9-2x Linear - Auto - Deep Blue Mica - Cold Weather Package - - Mods: Aero Rear Sway Bar, Perrin FSB, Whiteline QR RSB, KYB-G Excel Shocks, STI Pink Springs, Tsudo UEL, Custom catback with Magnaflow, Centric rotors & posi-quiet ceramic pads, 17" ASAs w/Dunlop Direzzas (summer), 16" OEM alloys w/studded Nokian hakka 7's (winter), 35% tint sides/rear

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#12 2020-09-16 14:33:24

supremekizzle
Member
Registered: 2014-08-05
User Number: 20841
Posts: 50

Re: I've got rot :( worth fixing? Pics inside...

jixaw wrote:

so far the rivets are good....used over 100 of them though smile...

I took out all the interior and started just knocking rust out...mine was as bad as yours...cutting away the rust revealed large gaping holes...i had to remove the seat back bracket and remount it after the repair...

once the rust was out i riveted some aluminium sheet stock pieces to cover hte holes..i dont remember how thick the aluminium was but i got it at home depot...after it was all riveted, i coated everything with tiger hair fiberglass....i globbed it on good and pushed int cracks....basically just putting a good layer all over the aluminium and covering the rivets...

I can give you more detials if needed....it took me a couple of days to do and i had a buddy give me a hand.....

I would like more details. A lot of the local welding and body shop people are saying they don't feel like taking the job on. hmm I'm on my own....

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#13 2020-09-16 16:08:01

jixaw
Member
From: Cambridge, MA
Registered: 2016-02-22
User Number: 35856
Posts: 184

Re: I've got rot :( worth fixing? Pics inside...

if you want to PM me it might be easier to chat on the phone ...


2005 Saab 9-2x Linear - Auto - Deep Blue Mica - Cold Weather Package - - Mods: Aero Rear Sway Bar, Perrin FSB, Whiteline QR RSB, KYB-G Excel Shocks, STI Pink Springs, Tsudo UEL, Custom catback with Magnaflow, Centric rotors & posi-quiet ceramic pads, 17" ASAs w/Dunlop Direzzas (summer), 16" OEM alloys w/studded Nokian hakka 7's (winter), 35% tint sides/rear

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#14 2020-09-16 21:14:03

supremekizzle
Member
Registered: 2014-08-05
User Number: 20841
Posts: 50

Re: I've got rot :( worth fixing? Pics inside...

So.... I've been tearing and knocking away at what I can.

There's a really thick plate of metal that makes up the strut tower on the exterior of the wheel well. This seems to be quite strong in all the places besides where the holes are. I banged as hard as I could with a screwdriver all over it and I didn't punch through except where I've already torn away. This thicker metal seems to be surrounded by much thinner metal that "straps" it to the car. This is also pretty good except where completely rotted already. Now.... I'm sure that the entire surface of inner and outer are covered in rust where the two are sandwiched together since the water gets in between these two layers. I've accepted the fact that the car is probably done for. I plan on getting a plate welded over the two holes that are completely punched through for the time being. I'm also going to spray rust converter in-between the two layers of metal. I know rust converter won't cure it, but I'm hoping it will slow the process for a couple years.

This is quite thick and strong. I'm going to remove all of this waterproofing (lol yeah ok...) And re-coat it.

https://i.imgur.com/fZa6JW3.jpg

Banged on this exposed "outer" plate with a hammer and couldn't punch through. I'm just going to cover this back up.

https://i.imgur.com/doTUned.jpg

There is absolutely no doubt in my mind that the two surfaces that are facing each other here are covered in rust along their entire surface. Water seems to get trapped here.


https://i.imgur.com/GRBkXyo.jpg

Last edited by supremekizzle (2020-09-16 21:16:41)

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#15 2020-09-17 10:27:26

jixaw
Member
From: Cambridge, MA
Registered: 2016-02-22
User Number: 35856
Posts: 184

Re: I've got rot :( worth fixing? Pics inside...

yeah looks like you have it cornered....you are doing pretty much what i did...finding good non-corroded metal to rivet to is essential...I had to bend, cut, and shape the alumium patches that i used...im sure theres still some rust lurking but it bought me a ton more miles...


2005 Saab 9-2x Linear - Auto - Deep Blue Mica - Cold Weather Package - - Mods: Aero Rear Sway Bar, Perrin FSB, Whiteline QR RSB, KYB-G Excel Shocks, STI Pink Springs, Tsudo UEL, Custom catback with Magnaflow, Centric rotors & posi-quiet ceramic pads, 17" ASAs w/Dunlop Direzzas (summer), 16" OEM alloys w/studded Nokian hakka 7's (winter), 35% tint sides/rear

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#16 2020-09-17 13:42:11

krazykarguy
Worst ninja editor, ever.
Supporter
From: South of North Carolina
Registered: 2007-04-06
User Number: 1944
Posts: 8653

Re: I've got rot :( worth fixing? Pics inside...

I'm glad I got rid of my 9-2x before this became a problem I had to deal with... It had just started when I discovered the rot (on a Vermont car) had set in back in 2015.

EDIT: thread with pics of mine:
https://www.saab92x.com/viewtopic.php?id=67234

Last edited by krazykarguy (2020-09-17 13:44:15)


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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