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As you can see the Z26 was starting to show the early signs of rust on the dog legs and lower rockers which might compromise the structural integrity. The soil in the northern half of Wisconsin is all sand yet they salt the roads.



Made new rockers with a 50" box and pan brake I made work buy me. Reinforced some of the inner sections with SS. Riveted everything in with 1/4" rivets. Sealed seams with a paintable sealer.


I filled the center with expanding foam which is confined within a cocoon of Naugahyde so as to keep it off the inner rocker walls. Its mainly there for sound deadener and added impact suppression.

Not quite I-CAR standards but Im mainly trying to keep the car alive and make it safer to drive. Also its a winter beater so who gives a sh*#!

On to the A pillars. Cut out the bad parts and formed a piece for the flat part.
Then pretty much freestyled the rest by forming a piece with a hammer and a "V"ed surface. Ive done this once before on my 92 GT back in 2000.

Mudded and hand sanded. I somewhat halfassed it. Once again, don't care.

I dont have pictures but after that I sprayed dupont self etch primer on the bare metal and roller primed it with automotive Omni primer surfacer. After the primer flashed I just tossed some base coat Aqua in a edging gun and sprayed a quick coat on the unsanded primer. I just wanted the car on the ground at that point and this makes it look decent. Later I will probably wetsand it flat and properly finish the paint job.

Woow seeing all this on most of the cars on the forum.. Makes me glad my car only has little rust, (and mud+oil lol) theres no holes on mine whatsoever, which reminds me i never uploaded my. Rust free pics lol(theres no snow here)


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Nice work so far! Im curious to see how it all looks when your done with it.

Yeah, im glad i dont have to deal with the rust out here where i am. BUt out here i have to deal with dry rotted rubber exterior parts. So, i guess, its kind of a trade off...

Lol so true! Most of my ruuber exterior is damaged thanks to the heat 23-45*C are my regular temps here coldest day ever i can remember was 15*c and it lasted one night lol


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Holy crap! I think you got my 95Z beat...and I put that one down. haha

Well you don't know what his rear spring area looks like.... He could just be dealing with very bad rocker rot and that's it.. My spring perches were beginning to disappear on ole red... which is not good.

I feel lucky. My Corsica has exactly zero rust.

Ya, I should have put a bullet in this car and kicked it in the river 3 years ago or so but you know how it goes.... everything goes one at a time first the shocks and struts then the rack then the trans and finally the motor. Its like damn I put so much in to this thing I can't just give up now... I hate berettas. Anyways heres a pic of it base coated which will basically act as a guide coat when/if I wetsand the primer and finish it.


And yes, fortunately the rear spring perches didn't get the same abuse the rockers did. If those were bad im afraid it would be bad news bears for the old Z26.

I know how that is. The amount of work in my 95 is what drove me to building a rust-free roller with most of my mods from the 95. And Jon, and Tyler... You're not alone Brad! haha

woody90gtz wrote:I know how that is. The amount of work in my 95 is what drove me to building a rust-free roller with most of my mods from the 95. And Jon, and Tyler... You're not alone Brad! haha

Yep, i wish i could go back and kick myself in the arse for trying to repair all of my rust, mine was not as bad as yours Godlike, but was still bad, i rebuilt the rear perches and sub-frame and put in new rockers, in the end it was a waste of a year of my life, since your re-welding and adding things the body loses a lot or rigidity ect, its cancer to me and once it starts it cannot be stopped..
More happy than you know for finally putting my s/c setup and forged engine in a body that deserves it, finally

Mine is inching closer and closer to this point. I'll be on the lookout for a new one in the next couple of years.

They should have made burritos out of stainless....
I should have made my rockers out of stainless It would be funny to see my Z26 at the yard all rotted out with mirror finish rockers hanging off it.

Or carbon fiber... HA!

Probably worst rockers on a beretta I've ever seen... and they got fixed!! Wow..
How about the other weak spots? Firewall, rear subframe near exhaust, rear spring/shock mounting?