Considering I'm embarking on one of the largest rust repair projects known to man(or at least the W123), I've decided to chronicle it here with pictures. I bought the car in April, 2008 for $1300 with ~245,000 miles on it. Mechanically sound. We weren't really looking at the rust and didn't know much about it, but I've come to find it has done extensive damage. Nothing structural, from what I can tell (car doesn't fall apart on bumpy roads), but it's nearing it. I've got a Lincoln Promig 130 MIG welder, a door and a fender for metal, angle grinder with attachments, and POR-15 paint and epoxy. I've been told by just about everyone that this isn't cost-effective (I've come to terms with that) and I've been told it can't be done. We can think of this as an experiment and hope for anyone else working on a project like this.

SO FAR: Repaired rotted jack panel with rust-free donor, patched surrounding rotted rocker panel with 22 guage to keep out water (temporary) and painted and installed factory-new front right fender.

CURRENTLY: Hole in trunk/rear left wheel well. Lesson: cut out ALL rust affected metal before butt-welding.

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition