In our last edition of Project AE86 Zach Mallin of ZSM Custom fixed all of the extensive perforation rust and hacked up quarter panels in the rear of our car, as well as a bent-up lower core support with broken welds. We also found rust going through the lower shock towers. Zack set about repairing this damage, as his specialty is doing restoration of Japanese classic cars.
Our poor shock towers had rust penetrating under the factory undercoating, water entering in cracks and being held there until rust went all the way through the metal. So far our rust seems to be starting in the seams of the chassis so now we know why seam sealer is important!
Zach cut out the rusted areas of the lower shock towers and welded in patches.
This is looking at the repaired shock tower from the wheelwell side.
This is from the engine compartment side. It is hard to tell the repair from stock, and it is stronger than stock.
