Mechanical Problems & Technical Chat - Rust in the engine bay

I bought my 95 Civic EX about a year and a half ago and noticed rust starting to form under the airbox. I tried putting some caulking over it to keep the moisture out, but that didn't seem to work. I pulled the caulking off tonite and found that it had actually rusted all the way through. I need to get it fixed asap, mainly because i'm worried about the pressure the strut absorbes just inches away and having that push all the way through. Any ideas would be great. I'm going to try to get to a body shop tomorrow, but wondered if there is anything I can do myself. Thanks

Post some clear pictures of the rusted area.

Caulking actually traps moisture that will create more rust. You will need to cut the rust out and weld in new metal.

I should be able to get pics up tomorrow. I was able to get to the body shop and they said that they arent able to guarantee the work it takes to cut the metal out and put new in, so they wont even do it.

get pictures of it.... depending on where it is... it might not be a structure thats to important...
if ya have a friend with a small welder you should be abe to do it yourself...
all it takes ia s cutoff wheel and air sourse and cut off ruffly an inch larger than the rust area. dont hammer the piece out! just cut it cleanly... then look at th eback of the rust area as much as posible and make sure you cut it out large enough..... then take your cut out section and transfere the exact shape to some new steel same guage thickness and then grind all the edges to ruffly 45degrees (for the welds to smooth out nicely and not be grinded off when you smooth them down) and get some magnets that will cover the gaps to hold the new metal flush and then just start tack welding it in. and after its fully tacked all the way around with no gaps then grind the welds smooth and paint or undercoat the area.

its not really difficult.... im sure the metal isnt very thick so most small welders will be enough.
but post pictures of your trouble areas... and dont use caulking on rust ever again!
for surface rusting areas you need to wire brush off all the rust as much as posible then use some stuff that converts the rust and then paint it or spray the area with ruberized undercoating.... dont just cover up the rust with paint or caulking or anything with at least removing all the rust!

Sounds good, I think that I might have a welder at my parents house. Would it be easiest to cut the metal with a plasma cutter?

if you had one sure.... you get a picture of it yet?

I'm gonna hafta get one tomorrow morning, my camera was dead when I went to go get the pic and I had a couple things to get done tonite. Sorry for the delay and I really appreciate the help

http://img.photobucket.com/albums/v448/itsgoindown05/SDC10045.jpg
http://img.photobucket.com/albums/v448/itsgoindown05/SDC10044.jpg
http://img.photobucket.com/albums/v448/itsgoindown05/SDC10043.jpg

In the second picture, the hole that rusted all the way through is just above the green tape and to the left a tiny bit. The rust isn't too bad, but I'm afraid that its in a bad spot with the strut just behind it.

well definatly odd spot to rust at.... i dont think ive ever seen one rusted there!

for that tight corner id just use some angle iron along the backside if posible. and just clean or grind off all that rust. im just shocked it actualy rusted there!

Hope you know someone who can do sheet metal work or if you do you are going to have to cut it out and replace with a new metal.

I think that it rusted there because of the windshield washer fluid. I was thinkin that once I can find someone to cut it and weld a new piece in that I will find a piece of rubber gasket to put along there and route the water and windshield washer fluid to a different location. Thanks a lot guys and if you have any other ideas about how to divert the fluids, go ahead and let me know.

for rust, i'd use POR15. its a rust preventative paint. u can paint it on with a brush right onto rusty surfaces and it prevents the rust from creating and spreading more. tho in your situation, the rust has already ate thru and your best bet is to weld in a little new metal. esp since its at the base of the shock tower.