Lower Rad Support Rust Repair - Got Carried Away

Nick Nicolas Sep 22, 2020

  1. Nick Nicolas

    Nick Nicolas Test Drive

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    Originally planned on simply welding in the lower rad support (ordered the OEM part), when I pulled it all apart I realized the rust was more severe than I had thought. Bought a new rad support and welder and taught my self to weld. The mounts were tricky, ended up using 4” square thin wall tubing mounted horizontally.

    8C65A133-18B3-4002-B834-40FD853482D2.jpeg 4F14B1A0-F9C6-4E01-A0E7-914AF3B6A8C5.jpeg 550C1A20-5969-4511-A215-F5AFC4E9B32C.jpeg 3CC4D3C1-7DDD-4A66-AC60-F7A5BBC2812D.jpeg 34D7EC1A-F37F-4BC9-88F2-2F6366CAA709.jpeg 98E3DF00-E420-4860-8386-8CD108D76DD8.jpeg DB19AA96-780F-4A2A-9B08-1C83A8D16E6D.jpeg DCED035D-1269-4A8C-B640-36A2120CD12D.jpeg 95EBD170-F043-40C8-A9B8-F6BB7443A7A4.jpeg 20B73A3D-D1E4-4406-B304-A11B9E38E72A.jpeg
     
    Last edited: Sep 22, 2020
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  2. Nick Nicolas

    Nick Nicolas Test Drive

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  3. Slapdash Racing

    Slapdash Racing Bought an X

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    Well, I guess you did get carried away! Thanks for the details. I'll be embarking on this same project soon enough. My radiator is currently held in with a few heavy-duty zipties.
     
  4. Nick Nicolas

    Nick Nicolas Test Drive

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    1B20955E-148C-40FB-A6F4-03250575F336.png Refreshing entire front end as well. Just ordered a bunch of parts.
     
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  5. Slapdash Racing

    Slapdash Racing Bought an X

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    Nice!

    Don't forget the control arm bushings. The ones that are on the truck are really a pain in the a$$. I had to reverse-mount a hacksaw blade and slowly cut off the metal part, then beat the bejeebus out of the thing just to get it out. Patience on that one.
     
  6. Slapdash Racing

    Slapdash Racing Bought an X

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  7. Nick Nicolas

    Nick Nicolas Test Drive

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    Yikes! I believe the arms I bought cone with the bushings already pressed in. Also ordered new mounting bolts all around, by the looks of the ones on there, they are rust welded in place.
     
  8. Mar10OR

    Mar10OR Test Drive

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    Most excellent work on that “rust removal”.

    I need to learn how to weld........
     
  9. Slapdash Racing

    Slapdash Racing Bought an X

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    Yep, you probably did get the CAs with bushings pressed in, but there's another bushing on the truck itself. You might be able to get away with it, as it might still be good, or maybe somebody did it before your acquisition (let's hope). I did it as a preventive measure 'while I was in there' sorta thing. Either way, good luck with the process!

    upload_2020-9-24_7-37-42.png
     
  10. Nick Nicolas

    Nick Nicolas Test Drive

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    All my parts arrived, but i didnt think to get that bushing. Id hate to pull everything apart and find out i need to replace those too. Of course nobody in town has any.
     
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  11. Nick Nicolas

    Nick Nicolas Test Drive

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    80247991-AFB9-4F48-97AE-2C91B3126CEF.jpeg Heres what i did for the body mount.
     
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  12. Slapdash Racing

    Slapdash Racing Bought an X

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    Shouldn’t be too bad. By the time you order it and it comes in you’ll probably still be disassembling all the other bits.

    I’d start soaking parts in PB now, particularly that bushing. Juice it once a day if you can.
     
  13. Nick Nicolas

    Nick Nicolas Test Drive

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    Front end refurbishment was a bust lol. The torsion bar was rusted solid to the front torsion arm and rear torsion adjuster thing. The old girl beat me lol. I ordered new torsion bars, adjuster things from 4x4 parts. Will have to cut off all the parts to finish this job. Wish me luck.
     
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  14. Slapdash Racing

    Slapdash Racing Bought an X

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    Oh, that sucks! I had to cut one of my torsion bars off (had new ones anyway) and it took a good day or two, on and off, to get the adjusters off -- and that was after about 17 gallons of PB Blaster. Good thing 4x4 has them because I think they're NLA from Nissan. Good luck and keep us posted!
     
  15. Nick Nicolas

    Nick Nicolas Test Drive

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    Still working on front end. Finally have everything off. Except those darn rear bushings (had to cut the bolt to get lower arm off)This is by far the most painful repair Ive tackled in a while. At least there wont be anything else to do when I’m done.
     
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  16. Slapdash Racing

    Slapdash Racing Bought an X

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    Yep. They are a huge pain in the arse. The only way I could do it was to chisel away some of the rubber (you could burn it too, but I wasn’t into that), then Sawzall a bit through the metal part of the bushing, then reverse mount a hacksaw blade and just start moving it back and forth without cutting the actual bushing mount, or carrier, or what’ver they call it (the thing that’s still mounted on the truck).

    You can try and tap it out with a big socket, or slowly with a screwdriver, etc.

    Just keep at it, keep your patience, and soak that Mutha in PB Blaster for all it’s worth.
     
  17. Springfield

    Springfield Test Drive

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  18. Slapdash Racing

    Slapdash Racing Bought an X

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    Location:
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    That does look like a pretty fair test! To each his own I guess. I happen to like the smell of PB over LW though, but that's my personal aromatherapy. I've heard about Kroil, but that's waaay to rich for my blood anyway, especially fielding a rally car and a 4x4. I also try to avoid heat, especially when there's rubber involved, as in this case, mostly because I'm afraid of burning my garage down if I'm not watching what I'm doing. Yes, I could take it all down and roll it outside, but sometimes that's impractical.

    That is a good test though and thanks for the video. Much appreciated. Now I know what not to spend on various canned, smelly, oily things!
     
  19. Nick Nicolas

    Nick Nicolas Test Drive

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    as it sits. Been like this for over a week. Hopefully finish up by nect weekend.
    85B602A1-09A7-4204-BA05-65880B76D38A.jpeg
     
  20. Slapdash Racing

    Slapdash Racing Bought an X

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    Location:
    Eastern CT
    I hear ya. And I definitely feel your pain — from personal experience.

    Just know that this is the roughest part. You will get through this, and it is so much awesome on the other side.

    On my phone, I can’t see where you’re from, but if you’re in New England, let me know. I might be able to help on site.

    Patience is the key. When you’re just about to stick a rag in the gas tank and light’er up, take a deep breath and back away slowly. Go do some gardening, or stain the deck, or shine your sockets.

    It’s gonna be good.
     
  21. TerryD

    TerryD Total Tease Supporting Member

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    I'll have to watch this test in particular but Liquid Wrench has proven the best in many tests I've watched like that. I've found that WD40 is better than a lot of other stuff as well in personal use so I normally reach for it.

    Kroil is good but after using it for years at work, I still feel like PB Blaster is better. But both are good.
     
  22. Nick Nicolas

    Nick Nicolas Test Drive

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    its been a rough road, just ordered OEM abs sensors too, you know since Im in there haha.

    i appreciate the offer to help, unfortunately Im in Canada(2 hours north of Toronto).

    thing will be mint when Im done...right ha!
     
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  23. Slapdash Racing

    Slapdash Racing Bought an X

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    Oh, yeah, that would be a bit of a drive!

    Keep on truckin'!
     
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  24. Nick Nicolas

    Nick Nicolas Test Drive

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    Finally. The sawzall got away from me and I ended up cutting into the metal beyond the bushing sleeve. Probably over kill but I welded up the cuts and ground it down. Finally this ugly chapter of the story is over haha. B2DD9B16-88C0-4203-8900-4E73C91161A9.jpeg
     
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  25. Slapdash Racing

    Slapdash Racing Bought an X

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    Yikes!

    That sucks but the results look great!

    At least you won’t have to do this for another 20 years.
     

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