[DML] How to know when a frame needs replaced

["Matt Spittle" <supermatty@xxxxxxx>]

My battle with frame rust has been ongoing since I purchased my car. 
I recently noticed while removing loose epoxy from the front end that
the front end extension is rusting from the inside out.  I know that
the rear part of the frame is also in this condition.  I removed the
rust and coated the exterior parts of the frame with POR-15, but I
can't get into the inside sections of the frame obviously.  

How long will my frame last like this?  I can't imagine my car is the
only one in this shape.  Even looking at Robert's Lotus swap on
Tamir's website, I can see that his frame was rusting from the inside
out when when he cut away parts of the rear part of his frame.  I may
be able to afford the stainless frame in a few months, but a lot of
other provisions will need to be made in order to swap the frame
completely, like moving the car to a different garage, etc.  

The toughest part about this has been that parts of the frame that
looked perfectly fine were actually rusted underneath.  On my car, a
single 3" crack in the epoxy somewhere can easily mean an entire
square foot of rust underneath.  The more I chip away at my frame out
there, the sicker it makes me.  

Any thoughts?

thanks,

Matt
#1604









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