Sock's 240sx Rusto Project (56k, tons of pictures)

sorry for being nosy, but i gotta ask, what happened to your hand?

on a lighter note, amazing work your doing on this project. i can’t belive your determination.

should pay off for ya. keep it up!

Awesome job so far! I used the soil bag trick to catch some parts I took off this week, worked great! :smiley: O and matty, I think his hand has a bit of glovitis. :wink:

~B

kinda looks like he’s wearing a vinyl glove

kinda looks like he’s wearing a vinyl glove[/quote]

Yup. The HomeHardware special - 100gloves for $9.

Today’s work - Welding!

First off, a battery box I picked up for $5.00. Smoking deal.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/01.jpg

Making a nice new frame rail.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/02.jpg

Some hot-hot-above-car action.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/03.jpg

Frame rail repair:
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/04.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/05.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/06.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/07.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/09.jpg

Next hole to cut out and fix:
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/08.jpg

Closed for the night.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/April28/10.jpg

Today was basically spent on my side trying to weld with only a little light. It sucked, but it has to be done. That new hole in the passenger’s rear rail, that sucks big time. I gotta pull the rear struts to have decent access at it and repair it correctly. Today’s work was fairly light since I only had about 2hours to spend on the car, but I still got some good work done.

thats crazy,

it looked real for a second

anyways, +1 for all the diy work

good to see another 240 not go to the scrapyard

Remember that rot hole from the last update? Today’s work involves fixing that and a good portion of the subframe rail.

Hole? More like canyon.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/01.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/02.jpg

A little grinding, sealing, and welding.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/03.jpg

Not really much to say for the next couple pictures. tldr: welding, choking, welding.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/04.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/05.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/06.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/07.jpg

The whole frame rail is just about done.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/08.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/09.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/10.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/11.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/12.jpg
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/14.jpg

Some grinding on the rear quarter rust.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/13.jpg

Closed up again for the day.
http://img.photobucket.com/albums/v374/sockington/March-16-240sx/May01/15.jpg

Really not much to say for today. Lots of welding, lots of grinding, lots of everything. I expect the next couple updates will be similar as I’m going to reinforce and reweld the whole rear frame section of the car.
Screw strut bars, I’ll have chassis rigidity out my ass.

Got something in the mail today.
http://img.photobucket.com/albums/v374/sockington/pedals.jpg

I expect to install them tommorow.

you mean his hand is not made of latex!!!

As predicted, pedals installed (well, only the brake for now).

Start things off with some more passenger side frame rail repair.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/01.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/02.jpg

Installing the brake pedal (that fucking booster bolt was a pain to thread into the pedal)
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/03.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/04.jpg

Rear lighting removed. Attempted to remove rear bumper cover to no avail.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/05.jpg

Undercoated my series of patches on the rail.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/06.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/07.jpg

Starting on that ocean of rust called the driver’s side lower rocker panel. New pinch seam ahoy!
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/08.jpg

Some more 1/4 plate used with the new pinch seam.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/09.jpg

Finishing up the pinch seam.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/10.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/11.jpg

Kind of got hot in the car. Set part of the carpet on fire. God damn.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/14.jpg

Closed up for the night.
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/13.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/may0306/12.jpg

Overall, it was a good day (4-5hours put in today). I’ll probably finish up that enourmous hole in the body work over the next couple visits. Looks like it’ll be an exciting week ahead of me.

Between all the time put in welding and hosting/posting pic’s I’m surprised your able to work on the car. :lol: :stuck_out_tongue:

I’m kiddin but seriously, have you figured out how much time you’ve put in so far? I am really curious (even though it’s prob best you don’t keep track) to see how long you spent in total.

The work is impecable man, seriously. I think it’s top notch and would trust you with a welder on my car anyday. :wink:

I was thinking about this today. :lol: I’m guessing it’s around 64-70hours at this point.

Should change your name to Fire Pit…

holy shnap man dude u r doing some amazing work there on that car, we at son salaute u sir Sockinton :bowdown: lolz

hey man exellent job ur welding is definitly comming along

the underbody looks just like my parts car lol, anyone want it? haha

where do u get the metal for the frame? i need to get some i have 2 small holes

I have the metal just kicking around in the corner of the shop. Bunch of round tube, square tube, angle iron, 1/8th plate, 3/16 plate, and 1/4 plate. Also, me fiancee’s uncle owns a machine shop, so I’m just going to go bug him about digging through his scrap bin.

I was just going through some totals on the car:
Cost of car: $100
Cost of undercoating and repair things: $42
Battery Box: $5
Total: $147

If you factor in time spent on project vs. how much I would of made at PartSource for work.
Old Total: $147
Time put in: $9/hour x 72hours = $648
Total invested (time and money) = $795

However, if I had a good body-man and repair shop do the work:
Average cost per hour of worker: $30/hour
Total hours so far: 72
Cost for professional work? $2160

Good thing I don’t count my time as being worth anything.

Today’s update is mainly body-work, so if you hate bodywork, you’ve clearly come to the wrong thread.

First off, finishing up the patch from last time.






Fixing the driver’s rear wheel well lip. New metal going in.



After doing some more welding and adding a small piece, I layed some long-hair fiberglass to start to make things look pretty.

After a coat of shot-hair filler to the metal on the wheel well and a quick sand, I began finishing up with a coat of lightweight filler.

More glass on the rocker, followed by sanding, followed by more glass…




My tools of the day

Doing some more work. Yeah, pretty boring.


Some rust I swept up from below the car. Quite the pile I got going.

Closed for the night.

I find it kind of funny that everyone thinks I’m talented with body repair - I’ve had no formal training with anything I’m doing or have I had much experience with any of the fillers. I have a rough idea of how things go together, applying them, and then sanding the living shit out of them. Bondo doesn’t resist water getting through, so I know to lay down some glass-based filler first, but other than that, it’s all guess and check.

Also, making rocker panels with a stick welder just sucks. It’s so god damn hard not to burn through the body metal.

If your blowing through, use a thinner rod, and less heat/power…

laying 2 different gagues of steel doesnt help either but its all grindable

What’d you use the beer bottle cap for? lol