BUILD-OFF CHALLENGE: Eisberg rustoration, Need some input... Options

[mbseto]

Funny, I am as nervous starting this thread as I was to start cutting into my car.

I resolved to start a rustoration thread when I made my first cuts, so here it is. I'm hoping the community will pipe in periodically with any, "Don't do that!", "Do it this other way!", "Do this first!", or "Don't forget this!" comments that are appropriate. Any and all guidance will be appreciated.

So here's the car as I got it, not quite a year ago:


Started out doing a little engine work to get it running, then drove it around a little bit before starting to take it apart. Took the engine out, put it up on a dolly, took out much of the interior and suspension, and this is how it sits now:






After cleaning out the inside and seeing the rust, it was hard to believe we were driving it at all. These are the first cuts, just straightening out the edges of the rust holes really.


More pics coming soon, I'll be documenting the extent of the damage and forming a battle plan.

[mbseto]

Results of electrolysis on the tank. I would turn on the battery charger and let it run overnight. The sacrificial electrode would get covered in rust and slowly the current would drop until it was too rusty to conduct. Each morning I shut it off and pulled the electrode out. After work, I would clean it up and stick it back in and do it all over again. This is the result after 4 or 5 sessions... before and after:



On a side note, my HF grinder spindle lock got really loose a while back and has been having trouble holding the spindle while I change discs. Took a few minutes and took the head off. Thought I'd take a look, although even 30 minutes is too much to spend fixing a 14 dollar tool. Turns out the casting broke away where it supports that little lock pin. Going to put up with it for now, if I get bored at some point I make get mix some JBWeld and fix it.