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When does "some rust" become "too much rust"?

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When does "some rust" become "too much rust"?

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Old 10-28-2018, 05:12 PM
bitemark
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When does "some rust" become "too much rust"?

Hi all, from Brisbane, Australia

I've got an 85 XLT RHD Bronco that I bought 4 years ago. It's been parked up for 3 years and I finally have space and time for a rebuild.

Firewall rust was always visible, so I thought my first job should be to pull the 351/C6 and the dash, to see what the damage is.

So - attached images show the damage. I'm not sure how the RHD firewalls are assembled for export vehicles - maybe mine was done by a dodgy Aussie welder being paid minimum wage, but there are big holes everywhere. Most concerning is the rust inside the windscreen scuttle/cowl area and the obvious holes in the firewall.

My question - when is "some rust" considered "too much rust"? I am happy to do the repair work myself (semi-skilled but willing to learn), including either patching, smoothing or firewall replacement if needed. Otherwise - should I ditch this body and look for a replacement - either a donor car or replacement? My build plan includes a 460 swap, and everything else reconditioned/improved to create a reliable Sunday driver. I haven't spent much money on this one yet, except for $10k purchase price plus my labour so far.

I'd appreciate any info on how to start this one, or whether to recycle this car and look for another.

Thanks Mark

Driver's side firewall:


Passenger's side firewall:


Transmission tunnel:


Inside cabin above transmission tunnel:


Inside cabin driver's side:


Inside cabin passenger side:


Windscreen scuttle - rust holes into cabin:
 
  #2  
Old 11-05-2018, 04:31 PM
Beechkid
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IMHO, as far as the firewall goes, I would just cut it out and build up a nice custom one....which you will need anyways because of the engine/drivetrain. The rest of it looks minimal except for the floors but, as long as the rest of the cab is in good shape...IMHO...go with what you got!!!!!
 


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