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CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

Ok, I finished stripping out my interior, and so now my attention has turned to the battery box. I figured it was pretty badly rusted, which it is. What I hadn't taken into account was the rust continues down into the firewall!

I can't see exactly how far it goes, but I'm going to peel back the firewall trim and see today.

Has anyone had this problem before? I figure I can just pull the engine and weld it up, maybe throw in a few chunks of lightwall 1" as a brace while I'm at it.

Joes924Racer · Posted: Wed Aug 13, 2003 5:30 am Post subject:

Yea it probly went all the way down to where the frame comes out.
Theres like a wall there that is curved and it could have a bunch of pinholes in it from rust mine did.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

From the top, I can see the rust is pretty bad, but I can't see more than about 6" down... the rust appears to be around 6" wide, so it's probably more like 10"...

Have you fixed yours Joe?

Joes924Racer · Posted: Wed Aug 13, 2003 10:26 am Post subject:

It helps to have the engine out.

_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

gwsg · Posted: Wed Aug 13, 2003 11:41 am Post subject:

On mine the rust didn't reach the firewall but it went through the bottom of the tray and came out through the mudguard just above the front wheel. About a 3" x 4" hole.

After cutting away all the bad metal treat with a rust converter [phosphoric acid or similar] followed by a coat of cold galvanising [zinc powder in epoxy] before sealing and painting.

Kill the rust totally dead or it will end up eating your whole car. Its like cancer.

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My 80 924 loves me.

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

Thanks for the tips, I hope it's not too bad... This is all because the PO sealed it up using canned foam and some cheap sticky paint. I even found a rag stuffed in there.

gwsg · Posted: Wed Aug 13, 2003 5:14 pm Post subject:

Bloody POs!
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My 80 924 loves me.

Joes924Racer · Posted: Thu Aug 14, 2003 2:19 am Post subject:

hahah-a its a goodtime to get some por-15 rust killer and try it out if you can find it up there.
_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

Once repaired, I'd suggest a final coat using a rubberized spray undercoating material. 3M makes a good one I've used with great success in those areas exposed to the elements. I would think that the rubberized coating would help prevent a recurrance of the acid eating away at things.
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'79 Eurospec 931

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

I think housing the battery in a sealed box behind the passenger seat should solve these problems in the future

But for now, I have to do some serious wrenching and welding. Good thing I'm going to school in the fall for my welding tickets

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

I'm beginning to hate the previous owner of this car.

I pulled off the insulation stuff on the passenger side of the firewall, which has been acting as a sponge for the last 2 years in pacific northwest weather.

There is rust all the way down the passenger side of the firewall, about 40cm x 10 cm that needs to be cut and welded. Luckily, it seems to have missed the bellhousing.

Well, looks like I have my work cut out for me, and I won't be enjoying the handling of this car above civilian speeds until I fix it.

Nuts.

Joes924Racer · Posted: Mon Aug 18, 2003 3:45 pm Post subject:

O man get the wire feed.
_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

wdb · Joined: 02 Nov 2002 Posts: 2024

hey joe , the last time we saw your firewall it had a sheet metal and screw patch holding it together . who fixed it and how

924RACR · Posted: Tue Aug 19, 2003 10:57 pm Post subject:

I too had this problem in my 82 931, completely tore it out and built a new battery box. Sucked, but at least it is now perfect!!!

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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

Sounds like a lot of work indeed

Got any pics Vaughan?