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How much rust is TOO much?

PostPosted: Sun Aug 25, 2002 8:04 am
by Dave D
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Well, my hunt for an XB is now well & truly underway & I have full financial backing from management (the wife) so I've been out looking. I know unless I buy a fully restored (read expensive) XB I'm going to have to cut some rust out, so I'm fully prepared to do that. However my question is how much is too much or more importantly what areas can be saved & what areas cannot??.

I have 2 XB fairmonts that I plan to go look at in the next week, one is fully optioned GT replica with electric windows, power steering, fact sunroof, air con & the long range 110L tank. BUT the owner tells me it has rust in the Bulkhead (I'm assuming that's what I'd call the engine firewall), both of the door sills & in the channel that the rubber seal sits on in the boot.

Are these 3 areas replaceable or not??

The other doesn't have any of the fancy options but only has rust in the guards & the lower rear quarter I'm told.

Any advice on what can be salvaged would be most appreciated.


How much rust is TOO much?

PostPosted: Sun Aug 25, 2002 11:36 am
by Wrinkles

sorta depends on what you want to get out of it Dave. If you're building a replica, and supposing you want to make it as realistic as possible, you don't really want a sunroof or electric windows. ....and it also depends what you're prepared to put into it. (time, effort, $$'s) Once cancer gets into certain parts of these cars, you could quite easily be up for lots of time, lots of effort and lots of $$'s. Guards and lower rear quarter rust repair sections should be readily available through places like Rare Spares/Grand Tourer/GT Ford Performance (this by the way is no endorsement. However, the management of any of the aforementioned company's is more than welcome to send some cash my way) If that's all that needs repairing on the "less fancy" coupe, I'd have to say go for it! (...and if that's the coupe I think it is, go for it!!) Not having seen the extent of the rust of the optioned one, it's a bit hard to pass judgement. ...but from the way you've described it, could be a big job. bulkhead, sills and boot channel are considerably tougher repair jobs than guards and quarters.

.......but hey.. that's just my opinion! 10 different people could give you 20 different points of view (and I hope they do... take the pressure of me feeling responsible for Dave's actions) the end of the day, it's your call.

How much rust is TOO much?

PostPosted: Sun Aug 25, 2002 1:03 pm
by roadwarriormfp

If the GT lookalike has a sunroof well that kinda cuts out the option of a madmax replica.

I dont recal Max's car ever havin that option!! lol

Firewall rust is a killer for sure... as its not a nice flat panel to replace. unless you went to the expence of making a flat firewall to replace it...

As a GT replica it might also be thrashed a bit!

Rust in the lower front guards is common... repair panels are available for these...

When you go look at them... wind down the rear windows and look inside is you can...(inside where the windows wind into.. look for rust in there..)... Look under the area of the rear window... and tail light area...and where the fuel tank attaches.. rust in the drivers floor pan seems common too.. (as the drivers side is always occupied with smelly sweaty feet maybe!?!?)

How much rust is TOO much?

PostPosted: Sun Aug 25, 2002 5:03 pm
by AussieCoupes

If it has rust in the mentioned places it probably has rust in the rear parcel shelf and other places that you really don't want to repair. There are plenty of good quality (ie rust free or mainly rust free) coupes out there, you just have to be patient and take your time looking for them.

What part of Aus are you in?


How much rust is TOO much?

PostPosted: Sun Aug 25, 2002 11:07 pm
by Dave D
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Thanks guy's, I can't tell ya how invaluable it is to have people to bounce this sort of stuff off. I'm in Victoria BTW & still seeking someone one else in Vic with a built/part built Interceptor to catch up with. Is Scott Smith on this forum??, or anyone else in Vic???

Don't worrie Wrinkles I won't hold you responsible, I'm going to see the non optioned Coupe in two weekends time (the guy is off fishing) & not having seen it yet it still sounds like the best one I seen (or rather not seen) so far, the other 5 where a bit sad looking (one had more rust than steel left) & I thing the guys selling them had them priced a bit high.

As for the replica side of things I'm not sure if I want to go 100% replica (for a start that would need a real GT base car) or weather to get close & then personalise a bit. Since max had the "Last of the V8 Interceptors" it must therefore make sense that there where others before his (maybe they had a sunroof lol). So I'm leaning toward making an MFP V8 Interceptor & not a replica of Max's one. One thing I am fairly certain of is that I plan not to hook up the zoomies but rather have a normal exhaust run under the car & then make a bracket that allows the fake tips to be bolted to the car when I want.

Now I just have to start working out the budget for the bits I need.


How much rust is TOO much?

PostPosted: Tue Aug 27, 2002 2:42 am
by XAMan

Hi Dave ... my 0.02 worth ...

I've had an XB Fairmont coupe, and XB GT coupe, two XC utes, a ZH fairlane and three 77 LTDs ... all essentially the same central bodywork.

Rusted out phlenum (?) chamber / firewall / bulkhead would definately scare me off as it usually is accompanied by rust in the a pillar where the doors hinge and , in the worst cast, rust in the inside of the windscreen pillars.

Even minor rust in the phlenum chamber will require the removal of dash / heater / aircond / and dash support to fix properly ... I've done it on my first XC ute and it was a nightmare.

The best advice has already been given ... be patient and buy the best most solid base car that you can afford / find.

I am selling ... don't worry I'm not giving you a 'schpiel' ... an XC ute on ebay that I bought for a project that I have now decided not to persue ... and looked at maybe 15-20 utes in and arround Sydney over a six month period but ended up finding a real rust free car in Brisbane and trucked it down ... well worth the effort!

There's a lot of junk out there but there are still some gems.

All the best and good luck.


How much rust is TOO much?

PostPosted: Tue Aug 27, 2002 11:19 am
by Brad

Hi Dave

Just saw a rear neat XB for sale today, it had a great body and Interior, but also had a vinal roof and only a 6 cyl, if your keen I can try and get a phone number, he was asking $3500. So, do you fancy a drive to Adelaide?


How much rust is TOO much?

PostPosted: Wed Aug 28, 2002 12:10 am
by Dave D


Thanks for that, & you would not believe it but I just found out no more than 5 minutes ago that I have to go to Adelaide next Tuesday & Wednesday for work!. So if you could get the phone number that would be great, it couldn't hurt to try & get to see it on Tuesday night. The more cars I see, the better chance I have of getting a good one. Do you know how far away from the city the car is??

If you don't want to post the guys details here, you can email me at


How much rust is TOO much?

PostPosted: Thu Aug 29, 2002 10:42 am
by Wrinkles
Dave D - want to get in touch before you go to Adelaide.. send me an email: 3wmcopy at aceradio dot com dot au ...I won't possibly get a chance to check email again 'til Sat evening - if you're going sooner than that, so be it.

How much rust is TOO much?

PostPosted: Mon Sep 02, 2002 1:41 pm
by Dave D
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Hi guy's,

Right now I have some more rust questions, I've just been to see an XB tonight. I was lucky enough to have a great guide tonight in Brad (Thanks again for all your help Brad).

The coupe looked good & didn't have rust in the major spots (the panel beneath the rear window had been replaced) but it had some bubbling along the roof gutters on both sides. Is this a show stopper or is it possible to clean that up fairly easily.