Pontiac Bonneville Club Photo Gallery
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Image search results - "rust"
01_Front_RH_Rust_40_percent.JPG
Right hand corner rusted422 viewsThis is the right front corner of the car, right behind the wheel, with the front fender removed. The small tube sticking out is the sunroof drain. You can see I have just started to cut away the rusted areas with a cut off wheel.
04_Front_RH_Rust_under_2_40percent.JPG
Looking Up at Floor389 viewsThis is looking up from underneath the car. You can see a hole right through to the interior.
06_Floor_Int_Prep_40percent.JPG
Floor prepared365 viewsThis the floor, passenger side. I cut out as much as I could that was bad and then added metal from here.
09_RH_welded_40percent.JPG
Right Hand corner all welded342 viewsThis shows the right front of the car after welding.
12_Floor_Partial_40percent.JPG
Floor Partial Reconstruction371 viewsThis shows the reinforcement I added to the interior. I bolted and welded a heavy piece of metal right above the lift tab. My goal was to make it possible to jack the car at the lift point, and I was successful.
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RH corner painted386 viewsThis is the RH corner after painting with POR-15.
17_Floor_Complete_40percent.JPG
Floor complete342 viewsThis is the floor completed, it was painted with POR-15 and then sealed with 3M seam sealer. As a last step, I pop riveted a thin piece of sheet metal (shown) where your feet rest. It didn't need to be very strong, I just needed to fill in the hole.
18_RH_corner_complete_40percent.JPG
Right hand side complete326 viewsThis is the right hand side, completed. I painted with POR-15 and used a 3M seam sealer to seal up any gaps. This all gets covered with the fender.
19_LH_rust_40percent.JPG
LH rusted379 viewsThis is the left hand side. It wasn't quite as bad as the right hand side, the floor was not involved.
21_LH_welding_done_40percent.JPG
LH welding complete310 viewsThis is the LH corner after welding is complete. I took a different approach than the RH side, it looks better but since it does not show, it really doesn't matter.
22_LH_painted_40percent.JPG
LH side painted384 viewsThis is the left hand side after painting. I pushed the sunroof drains into the car when I was working on it, and then popped them out when done.
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Front342 viewsAmazingly, this car has over 230,000 miles and very little rust.
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