So... what am I looking at here?

[ABigBadZebra]

I wanted to get your opinion on how bad this rust is. I'm likely going to do the cutting, grinding and welding myself (I'll be learning as I go). I don't feel that this car is a rust bucket, but it needs some work in some very specific areas and these areas look hard to fab for. I'm just looking to see if I'm getting over my head. I'm pretty handy, I'm a sucker for detail.

One other spot to note that I don't have a picture of: Below rust in the first pic, rear quarter, where the inside of the trunk meets the quarter (which is approximately at the first bend in the metal that makes the flare of the wheel well), there appears to be some rust on the inside where this meets, and although the rust can't be seen from the outside, it almost looks like the metal has cracked right along this line, which is visible on the outside. Probably won't know more until I sand away the paint, I know. It looks like maybe an opportunity to tub the car.

I was going to post a bunch of details in these pics, but you guys just give me your opinions. Thanks!

 

[pontiacgp]

if you are going to redo that car I would suggest to take the body off and get it media blasted.....or find a cleaner car and use this one for parts...

 

[565bbchevy]

Typically when you start cutting rusted areas out for repairs you end up finding even more rust as you go and you have found quite a bit already.
It also appears that there is probably hidden bodywork under that paint job where other rust might be hiding.
And short of being dragged out of a swamp that is one nasty looking undercarriage and if you plan on keeping it and fixing it properly I would also say remove the body from the frame and get them both blasted and assess what good metal is left and decide if you can handle the project.
Sometimes you just have to know when you are over your head and know when to walk away even at a loss.

 

[lilbowtie]

Ditto the above, I know I would walk on this one. Looks like an older resto w/ some deep rust problems. I think if you put pen to paper you would be surprised how much you will have in sheet metal, patch panels, and weather stripping let alone the countless hours of labor. If your up for a challenge and ready to spend some bucks - go for it.

 

[ed1948]

From my experience working on rusty cars - visible rust actually means there is at least twice as much hidden rust.

 

[ABigBadZebra]

Well, that's pretty unanimous...

I knew it was going to be a project, but there is more rust than even I originally thought, and in some shitty areas at that. The work (labor) itself doesn't bother me but money isn't unlimited. I was hoping the fact that the car cost me nothing (a gift) that the cost to do this project (likely spread over several years) wouldn't be too outrageous. If my dad didn't give it to me, I'd probably just sell it as is and pocket some money, but it has sentimental value.

I'm committed to stripping it down as far as I can and jacking it up best I can to really check things out. If it appears worth it, I'm going to take 565's advice and get things media blasted to see what I'm working with. If it's workable, I'm committed to learning new things/skills and do what I can myself. If it's not, I'll at least be able to tell my dad I tired.

We'll see what else I find. Do you guys have any ballpark on what it would cost to get things media blasted? I'm in Indiana if that helps.

Oh, and no swamps as far as I know, but it did sit outside (on gravel), uncovered, for about 7 or 8 years.

Appreciate the input, guys!

 

[ed1948]

-how solid is the frame after the rear axle?
There are repair kits available.
If your work time is cheap(diy) parts are available for almost any body damage repairs.
Sentimental value aside, any parts and labor costs you put in you will likely never get back.

 

[el camino ss 84]

For what needs to be done. I would say keep it cause no matter what malibu you find around the quarter windows there always going to be rust which is a common spot and the bottom of the doors. so if you got two doors,fix the hood or get a different one, fix around quarter glass and the floor board it's will be cheaper than getting another one.

 

[ck80]

You have a couple challenges with that car, as I think you already know.

1) Reproduction panels are harder to find for the malibus, not many are being made and the ones that are typically are full or half panels, not small patch pieces like other models have.

2) The kind of rust I see here... you're going to have issues in the future. That car shows signs of rust inside the cavities that were naturally left when the car was built. Blasting will clean off what it can get to, but can't get at the inside. Once you get the car cleaned up, visible rust repaired, painted, I'd recommend drilling oiling holes with the rubber plugs and liberally keeping that body oiled up inside the cavities. It's messy as it weeps out shortly after the treatments, but, if no oxygen can get to the rust it stops progressing.

3) there's no way around it... you're going to need to buy and replace most of the bolts on that car, and as you disassemble things be very weary of capture nuts breaking loosee and the dreaded gm clips snapping and then spinning as you turn the bolt heads.I spent a good bit of time cutting up rusty cars like that. Long needle noses, long shafted flat head screwdrivers of varying thickness help, but it's going to be frustrating.

I wouldnt be surprised if bushing holes have enlarged behind the rubbers either, and would be concerned about the strength of some of the pitted metal parts (control arms, etc).

Now... nothing wrong with sentimentality and wanting to fix/save the car.

If it were mine I'd have a recommendation: try to find a clean non-rust belt malibu that was hit in an accident but not practical to fix (rear ended, hit on door and bent roof, or t-boned roof and quarter panel) that way it will be super cheap. Makes a perfect donor to cut all your patches out of, gives you extra hardware that's rust free.

 

[Texas82GP]

This wrecked shell fits the bill relative to what ck80 describes above and may still be available but I wouldn't wait long too contact the owner if that was the way you wanted to go......
https://gbodyforum.com/threads/well-the-unthinkable-has-happened.60273/
Anything can be fixed with enough time and money. If this is something you really want to do, then this thread should provide inspiration.....
https://gbodyforum.com/threads/81-oldsmopile-g-body-rust-repair.55800/