I bought this 91 z28 2 weeks ago. I knew I was going to find rust before I bought it, I looked the best I could from what little knowledge I have. After I got it home I started tearing things apart hunting for rot, I found it. The body panels are in decent shape, but the stuff you cant exactly replace is in need of repairs.

*The engine bay has rust on what I think is the firewall area ( pictures to follow ) .

*The under body has surface rust and have heard of a product called rust bullet I was thinking about going with.

*The driver side of the A pillar was repaired previously, I could tell through the primer. So I sanded it down and it looks to me it needs to be re-repaired maybe with sheet metal ( advice on that ? )

*The driver side rear wheel well is holding water under the ?glove box? ( pictures to follow ) I tested the metal and it seems strong still but I don't know what to do here. I think I fixed the leak that was causing it. The spoiler was letting water in ( I think ) So I took it off and and cleaned up the old silicone and laid down some new. Also there was 2 bolts missing completely that water could easily get into so I sealed them. Also, the only way I could drain some of the water out was to pry off this makeshift seal I found under the back end attached to the compartment. I'm not sure if that was supposed to be there but I killed it. I bought some gasket board and thinking of covering the hole back with it ( Will that hold with silicone? )

*Rear of the car has rot around the light housings bolt areas. It's not super bad but it doesn't look like an easy metal job ( i don't even know what an easy metal job would look like but this cant be one ) I forgot to take pictures of this while i had the car apart so I will update with that as soon as I can.

Other than this I have not discovered anything else yet. I have not lifted the carpet to take a peek but I have gone under the car and couldn't see anything.

I live on a military base so we are not allowed to tear down vehicles and such ( looks trashy i guess but I'm from Georgia and don't mind) . I instead have to go to an auto care center here on base, they have all the big tools I'll need there, lift, welder and even a paint room. The problem is they charge by the hour/day for usage and this vehicle is now my daily driver until my motorcycle gets finished. I'll have 2 people helping me but they are inexperienced also.

My intentions here are :

A: Understand what kind of problems I should expect.
B: Understand how to effectively disassemble the engine to get to the firewall ( I assume I'll have to.. )
C: Learn the best methods to fix the individual problems I'm facing.
D: Make a check list so when we get out there its bam,bam,bam done.

My intentions at the shop are :

A: Find and eliminate all rust and prevent further damage to the body.
B: Coat the under body with rust prevention ( Rust bullet?)
C: Paint the vehicle ( If time allows ) I have 14 hours of shop use on week ends only

Thanks in advance!

Picture of : Engine bay ?firewall? / Water inside the back fender well

 

More pictures, engine bay, under hood near head lights, car in whole

 

Rust repair that needs to be redone

 

I hate to be the bearer of bad news, but you have got some serious issues there. You may be better off just driving it until it no longer passes inspection, and then look for something else. If you're in the military you can typically find some really nice rust-free cars down south. I picked up a 2nd gen Camaro years ago in Louisiana that was 12 yrs old, but the underside looked like it just rolled off the showroom.

I say this with the understanding that I am not a bodyman or welder, but have dabbled in both.

 

I've never seen rust like that by the brake booster. Usually it's under the heater box. I'd look into getting some rust converter (Rust Bullet, Por15), and maybe some new metal for that area. I doubt you'll fine a repo piece for that area. So either make your own or hit a junkyard.

I wouldn't worry about the area by the head light, looks like it's just the flange for the fender. The core support looks good still. You could even trim that corner off (unless there is more rust under the fender).

The water in the rear could be comming from the spoiler, hatch gasket, wheel well, area behind the ground effects. If you think it was comming from the spoiler, that should be an easy fix. If it's from the gasket, another easy fix. The wheel well or area behind the GFX is alittle more complex. There is a seem in the well where water can come in. The GFX will hold moisture and cause the metal to rust.

The car doesn't look too bad, but it has been repainted. Or is it in primer right now? Kinda hard to tell with the wet pictures (I'm thinking paint, since the emblem and handle is on). No telling what is hiding under the paint though. I'd be most concerned with the firewall.

 

Not trying to bum you out but, that looks like a lot of restoration. ( time and money)

 

And I am a bodyman. The area of the firewall thats seriously rusted thru is made up of many different pieces and put together in layers. It also collects a lot of water and directs it outside the car. Some things just aren't worth it and I hate to say this may be one of them.