Changed the oil/filter yesterday on my '94 4.0 Aero and she was actually about 1 quart low. She's got a very hard 200,000 miles on her and I'd say only burning a quart in the last 7,500 miles since last oil change is pretty good. I'm a contractor and it is a cargo van, I'm gonna miss her when I have to retire the old girl. But that won't be for a while I hope.

My question is this: I live in the midwest which = snow/ice which in turn = lots of salt in the winter. The rust is starting to get bad, would it be sensible to grind the rust off the lower panels and then just have the lower 1/4 LineX'd or Rhinolinered? Do you think either of those would act as a rust inhibitor? Other option is to get diamondplate aluminum and do a cover up job on it. Don't wanna throw a lot of money in it, simply because she's about on her last leg. However, I do need it to look somewhat presentable when going to peoples houses and doing remodels. Gotta look professional...image is 1/2 the battle.

Added note: The 200,000 miles is on the original engine and transmission. Even the Radiator hoses are original. Only had the fluid in the tranny replaced 1x. Only things replaced: water pump (twice), battery, belt, brakes, tires, alternator. I think these vans are the best van EVER built. Wish they'd never have discontinued them.

 

i would do the diamond plate over the top...good machine shop can bend to fit the contour...use marine grade diamond plate alum. alloy to stand up to the salt.
will give the Aero that retro commerical industrial look

 

I agree, but before doing that (if you have the tools) is to grind/sand off as much of the rust off as you can and use a high quality rust inhibator. They are availible at any parts stores for about $5 a spray can. Rhino linning and the such will prevent rust, but you are looking at big bucks to cover up a problem that won't be fixed by this product.

 

I agree, but before doing that (if you have the tools)

lol...umm I have more tools than most Sears' stores. I should search I bet they sell such body molding kits somewhere. Every aero around the midwest seems to rust in the exact same spots as mine have.

 

Wow, and I thought mine was low maintenance. Your record makes mine a bit high. There was a product a while back that I liked to use when I lived in Omaha. I believe it was called Extend. It was a white cream when applied and as it reacted to the rust it turned a glossy black. You could then paint it to the color you like. For appearance sake I would go with replacement panels over the affected area and then a nice paint job. Diamond plate look like what they are, and that is that you are covering something up.

 

most of the body cancer is from the inside of body cavities.... road dirt, salt and moisture set in there protected from all the washings and waxings, eats away on the metal 25/8/366
body and frame not sealed, only spot welded every few inches and with drain holes

 

Translation please?

 

i believe it's an exaggeration....25hours a day/8 days a week/366 days a year.

 

i've seen 3/4 ton Ford frames ate thru from beach glass ball drift driving in the winter storms, 2 winters.

 

Huh?

OT, I had a '78 Bronco that lived almost all of its life in omaha, man that was rusty (yes if I lifted the carpoet I could see the highway), but people would always get out of it's way.

 

beach glass ball drift driving.....now that is a new one to me.

 

This may be blasphemy but why not consider replacing it with a full size van? I would think a 150 would be more useful to a contractor. Ladder rack, full 4X8 sheet capacity, etc. I use my old Dodge often when projects come up. Sometimes the load is worth more than the van :-)

Better for the image too IMHO.

 

I think road salt should be outlawed. We can put a man on the moon. Why can't we develop a chemical that will melt snow and ice on the road, but not be corrosive? I forget what few states do not use salt in the snow belt, and rust is hardly an non-issue on all makes of vehicles. I feel for those of your Aerostars with rust. My '87 Aerostar here in the Sacramento valley of California, is as solid as the day it was built in MO. It would KILL me to see this Aerostar with rust!! Although the bumpers, and rear hatch areas don't rust because they are non-metal. This truly is an uneccessary waste for Any Aerostar, the RUST Factor. Ed

 

A car-wash does wonders against road salt. We wash all of our vehicles at least once a week during the winter, and have never had a problem with rust.

 

no road salt used here in 10 years....DOT only uses a bio chemical spray that works better than salt and no corrosion...lasts for weeks...bridge steel and rebar don't rust out and guard rails don't fall off.