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In furtherance to my intro post "greetings", in reference to a 2005 taurus se, well I finally got the car home. Its in the garage, up on blocks, and i want to tell you, it will be a major undertaking to resurrect this poor thing. But try i will. ;)
What did I do...... To date, I have the interior out, front clip off, the exhaust laying on the floor, the motor supported by block and chain from rafters with the front subframe sitting outside. Today i disconnected the gas lines and electrical from the tank. Tomorrow i will remove the tank and lines, that will give me clear sailing to go at the undercarriage with the air chisel.
What did I find...... unbelievable that a 9 yr old car could be so rust riddled. Passenger side control arm front bolt completely rotted away from frame. The drivers side is just about ready to break away. The good news is that the body mounts are still solid, making a replacement frame feasible. Sadly though the passenger floor front and back are rotted out,including the body frame rail. the rockers are rotted, the inner fender around the strut housing rotted through and the list will go on. Cheers for now. car (1280x960).jpg

floor (1024x768).jpg

back floor.jpg
 

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Wow.... I feel your pain. My 2005 is a mess, and the 2006 is getting worse and worse.

Look forward to seeing what you do to get this poor car back in shape.
 

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HOLY **** that's some horrible rot you have there!! Good luck but that would be the point in which I would give up. I just hope the mounting locations aren't rusted though as well. Good luck!
 

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do you think your 05 had a bad galvanizing, or have you seen this as endemoc of 05 and 06, or is the salt in your area really really intense?
 

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Man and I thought mi car was bad. I got a softball size hole under the driver side rear door. Ima try to attack tht rust this spring
 

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Discussion Starter #8
do you think your 05 had a bad galvanizing, or have you seen this as endemoc of 05 and 06, or is the salt in your area really really intense?
My opinion,living in the maritimes, where salt is bad, coupled with the low mileage(54000, meaning it sat a lot) may have contributed to the abundant rust.It looks as though it may have been parked on grass for most of its life, as the damage seems to be pretty far advanced for the cars age. Having said that, it appears that the control arm breaking away from the subframe is a common issue with these cars.

a few more pics. take note of frame rot around the control arm bolt. cheers control arm.jpg

frame.jpg

mount.jpg

rocker.jpg

support.jpg
 

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IMO...... it's WAY passed it's usable life. I'd find a good body with a blown motor/trans and swap what's good from that into the other.
 

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Discussion Starter #10
IMO...... it's WAY passed it's usable life. I'd find a good body with a blown motor/trans and swap what's good from that into the other.
You may have a valid point there sousa. Tomorrow after i finish removing the gas tank, I will be taken the air chisel to the rear frame and suspension components. The integrity of these will be the determining factor of weather I save it or not. the floor, rockers and towers wont be too bad of a fix. BUT if its going to mean a lot of welding while laying on my back underneath it, then im getting to old for that ****e. lol. cheers
 

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In furtherance to my intro post "greetings", in reference to a 2005 taurus se, well I finally got the car home. Its in the garage, up on blocks, and i want to tell you, it will be a major undertaking to resurrect this poor thing. But try i will. ;)
What did I do...... To date, I have the interior out, front clip off, the exhaust laying on the floor, the motor supported by block and chain from rafters with the front subframe sitting outside. Today i disconnected the gas lines and electrical from the tank. Tomorrow i will remove the tank and lines, that will give me clear sailing to go at the undercarriage with the air chisel.
What did I find...... unbelievable that a 9 yr old car could be so rust riddled. Passenger side control arm front bolt completely rotted away from frame. The drivers side is just about ready to break away. The good news is that the body mounts are still solid, making a replacement frame feasible. Sadly though the passenger floor front and back are rotted out,including the body frame rail. the rockers are rotted, the inner fender around the strut housing rotted through and the list will go on. Cheers for now. View attachment 82849

View attachment 82881

View attachment 82889
Fred Flintstone would feel right at home.... ;)
 

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That's way to extensive for it's age. However if the car parked most of the time in grass, that could explain the excessive rusting. Not to mention if it's wasn't driven much. Before my grandfather passed away he bough brand new a 2000 chev S-10 4 wheel drive. He kept it for 5 years and only had put 20,000km on it. I looked it over thinking it would be a good truck for me to buy as he couldn't drive no more. It looked excellent shape from above, looked at the frame and everything underneath and it was that rusted the heads of the bolts for the brake calipers were rusted to the point you wouldn't get a socked on it. Not to mention the frame was heavily scaled, brake lines were going to need replacing, just way too much work to put into it.
 

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Discussion Starter #13
Well after days of removing scale, I decided there was enough solid metal left(structural and alignment integrity intact) to weld new metal to. So the project is a go.:eek:. Being retired, it will keep me busy hehe.
Its always been my policy to tackle the worse first, so the passenger side it is. After cutting the rust out from passenger floor and unibody frame rail, I found that the subframe mount needed a little attention. Finished that, sorry pics didnt turn out, then moved on to the floor. I need a piece about a foot long to fix frame rail. I will take the piece I cut out, into a shop and have it made. The floors are constructed in sections, overlaid and spot welded, i assume for added strength. Today I roughly fabbed the 1st section of floor pan and tacked It in place. The old eyes and body refused to do anymore lol. Tomorrow, i will hammer and tack until I get the fit i want. Cheers. use2.jpg

2use.jpg

1use.jpg

3use.jpg
 

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Discussion Starter #17
Today I finished up with the passenger front floor(patching). My plan, once i get it cleaned up is to treat it with metal prep(a rust converter) then coat it with por15( an excellent paint over rust finish).By the way I found a good sub frame for 200 bills. thought it was a good deal. cheers.

Oh yeah, i included before and after pics of a 75 jeep cj5 (just for giggles for those interested) that i found rotting away in a field. It is a frame off restore(rust damage was way worse than the taurus) 1 use.jpg

2 use.jpg

3 use.jpg

4 use.jpg

Picture of me 1.jpg

jeep.jpg that I Still have a ton to do to. hope you like.
 

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Discussion Starter #18
Got a late start today(errands), worked on the car from noon to 330. Cut the rust from the rear passenger floor pan, pretty much all of it lol, got it ready for a new piece. Took measurements, and with a few bends and cuts in a piece of sheet metal, came up with a rough replacement pan. Got it tacked in for now, will finish it up tomorrow. Appears i'm out of seam sealer, another trip to town haha. Hope to get started on the drivers side tomorrow. PICT0064.jpg

PICT0067.jpg

PICT0071.jpg

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use 2.jpg

use1.jpg heers
 

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Lookin good! Keep up the great work.
 
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