cavalier gsi rust

[joeleeman]

after removing the rear axle and components for refurb off my gsi today i found were the springs meet the chassis rail has rusted right through, just wondering if anyone has come to this problem befor and how to resolve it
cheers

[Paul]

Yeh common on these
How to fix? Get welding.

[specks]

this is the most common problem with a cavalier,just get the rot cut out and weld new metal in,thats it tbh.

[joeleeman]

how about the steel upper spring seat section thats welded on? just fabricate some up?

[Peteyboy_essex]

The parts are getting hard to come by now, so fabrication is probably your best bet. The rear chassis rail is made up of 3 layers in that area. You can either mak eit up layer by layer, or use thick sheet steel to fabricate from.
Its quite an awkward job and you best off dropping the fuel tank and the entire rear end off the car to do the work

[adymorris]

can't buy chassis legs any more - I had the same problem - used a piece of cardboard to make a template, cut some metal to size, chopped out the crap and welded in the new legs








Have you dropped off the side skirts and checked your sills yet - if not do it real soon !!!

[joeleeman]

no not yet, dropped all rear axle and fuel tank, how do you remove skirts?

[specks]

they just unclip.

[Peteyboy_essex]

take the clips out from under neath, and lift/roll the skirt upwards, hopefully you wont break any/too many clips

[joeleeman]

what size plate do i want to use

[adymorris]

I used 3mm - will outlast the rest of the metal on the car