Okay, living in the "salt belt" (read; northeast Ohio) I have SEVERE rust on my 92 Aero.

It is in the usual place, rocker panel meltdown! I have running boards and they are causing the left front fender to pull off and rub against my driver's side door.

I am ***-uming I need to trash the running boards in order to salvage my rocker panels and front fenders.

Am I right? How do I get those suckers off? I mean, what size ratchets (or whatever) do I need?

The engine and everything else is in GREAT working condition and I don't want to get rid of her. I want to keep her till she's dead, but I also want her to look fairly decent as well.

Any suggestions or input? It'd be much appreciated!

Thanks!

aerostargal

 

same here... mine's a 89. mechanically she's a champ! but aesthetically, she has loads of battle scars with rust. i wish someone would make replacement panels for our aeros in fiberglass. it will never rust again!

 

have you found this site yet http://www.showcars-bodyparts.com/aerostar.html

 

AerostarGal, what part of Ohio? I grew up in Austintown, OH (Youngstown OH) I remember the Ohio winters, but don't miss the salt trucks! Here now in Sacramento, California, my '87 Aerostar is solid as it was when new. You would think if we can put a man on the moon, we could figure out how to melt snow and ice on winter roads, without the rust it causes? Even here in Calif. I still wash and flush the underside of my Aerostar. I guess old habits are hard to break?! When I lived in Ohio, I was always washing the salt off my truck, and it did not rust, until 9-10 winters, when I was getting blistering under the paint... *sigh* Ed My muscle cars ('71-74 440 Dodge Chargers) were always stored in the winter

 

I'm working on my mint 96 to keep it from ever rusting. Any advise? Anybody.
Anyone want info on what I'm doing just ask. My 94 is gone my 96 won't go that way if I have a say in the matter..

Dick

 

i recall someone posted that site before and didn't recommend buying from them. *shrug* either way, tho the parts exists... just too costly to get it up here in canada. however that tilting hood - if it includes the side fenders - would be great for spark plug work!

as for keeping your 96 aero in good shape... keep the drainage ducts clear and clean. try not to keep the salt on the body for too long.

 

as for keeping your 96 aero in good shape... keep the drainage ducts clear and clean. try not to keep the salt on the body for too long.[/QUOTE]

I'm into some serious changes to the way water gets into the rockers.
Up here in VT if you don't the van is gone in 100k miles. Many hours are going to be employed to fix fords mistakes.


Dick

 

Ed,
I live in Tallmadge which is just NE of Akron. We have been here for 8+ years. I am familiar with Youngstown - hubby and I go shooting at a rifle club there on occasion. Lots of fun and oh-so-stress-relieving!

All,
Are there any tricks to removing rusty bolts from the running boards? I still have no idea what size wratchet to use to remove them. I figure that all I have to do is remove the bolts attached to the fenders and then the running boards will just fall off .

I don't care if the rocker panels (or what is left of them) look bad, but I just don't want to have to replace my fenders as well.

In the meantime, I have been searching the web for another Aero, but I can't justify spending the $$ on something I have no personal repair/maint history on. With my girl I know what has been repaired when and how long ago. If I get a different Aero I may just wind up putting money into some of the same repairs as I have with my '92.

Yes, I would like her to look sharp, but right now my main concern is mechanical longevity!

Wratchet size anyone?!?

I know she will continue to rust at this point, but I have to get these boards off before I wind up driving around in just a chassis with a drive train

Thanks again all,
aerostargal

 

try spraying the bolts first with Liquid Wrench (availible everywhere,) and let soak for a couple hours. That will help with the rust.

Not a clue what size bolts your running boards take. Could be Metric or SAE. There is a socket called "the Gator" found at your super stores in the auto section that will form the shape of the bolt head. Worth a shot for $20.