How To Repair Structural Rust Damage

Every situation is unique when it comes to rust and structural repairs like this. Consider this video a basic guide to structural body repairs, and nothing more. Note that some repairs are not practical or structurally possible. I recommend consulting with a body shop before performing a repair like this on your own to see if it’s worth the effort first.

That said, this video shows how I repaired the unibody structure where the rear subframe mounts on my 2003 Honda Pilot. Apparently this is a very common problem with these vehicles as well as Honda Ridglines and Acura MDXs of the same vintage. If you’re able to perform this repair yourself, or have someone do it for you, it can save your vehicle from the scrapyard.

Video of rear suspension removal on this vehicle: Video link posted when available.

Thanks for watching!

#ETCGVideo #ETCGHackHawk

Tools (some are affiliate links)

Parts

Subframe Bolts: 90160-S0X-A00

I used 16ga steel for this repair.

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Due to factors beyond the control of EricTheCarGuy, it cannot guarantee against unauthorized modifications of this information, or improper use of this information.  EricTheCarGuy assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. EricTheCarGuy recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video.  Due to factors beyond the control of EricTheCarGuy, no information contained in this video shall create any express or implied warranty or guarantee of any particular result.  Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not EricTheCarGuy®.

[Romif_SK]

I started watching your videos when I was 17 years old. I learned a lot from yours videos. Now almost 10 years later I work as technician and honestly I don't know if I would be where I am without your content. So thank you Eric.

[toddcott]

This is the sort of rust damage that puts the car in a scrap yard. A first class job, sir.

[roddydykes]

If anyone wonders why rust repairs are expensive, this is a good video to show

Inspiring work as always

[laszlototh]

It is amazing how Eric's fabrication skills developed during the years. This was a pleasure to watch!

[martij]

Hey Eric I just want to take a moment to thank you. I've been watching you for a couple of years now and I have learned so much. I'm a university student and I work on cars (both my own and those from family members/friends) as a hobby in my spare time. However when I visited a highly praised shop in my area to get some springs compressed (as I don't have the tools for that) they were so impressed by my work on cars that they offered me a part-time job as a mechanic! This was such a compliment for a hobbyist like me and I owe you a big "thank you" for learning me so much throughout the years. Keep on wrenching and I'll keep watching!

[panzerveps]

You might not be a fabricator, but that's a job well done.
A job like that requires the ability to plan ahead and visualize the next couple of steps.

[codybechardwatson]

I just did a 97 CRV, where the trail arm bushings mount up. It was my first go at fixing structural rot, and I'm very happy with the results. I ended going with what your original plan was, welding a nut behind the first layer. I did not consider it needing movement, however after watching this I am still pleased to know someone with much more experience then I had a similar idea. Very confidence inspiring. Thank you!

[MrAceyJay]

"Grinder and paint makes me the welder I ain't"
Nice job. Sure there were other ways it could have been done but nothing wrong with the way you did it.

[Gmacc]

Hey Eric I bought a Chevy Malibu from my brothers mechanic "friend". A few years ago I would've been screwed. Now if days I see it as more of a challenge now. Your videos have been crucial for me taking my vehicle maintenance into my own hands. This year I'm going to a trade school to be an automotive technician. You'll never understand the positive impact you've had on my life. And without a doubt I wish to pay that positivity forward by being honest and thorough like you are. Thanks for all you do Eric.

[MikeFord]

Hi Eric, weld through primer is a great product to help reduce corrosion on the surfaces you cant get to after welding.

[iblistarhun]

This was very impressive, Eric. Well done. I'm a layperson (my work is in IT infrastructure so my tools are all virtual and not physical) and I enjoy watching your obvious skill and experience in a domain so clearly different from my own. Very cool.

[cityside]

Your comments about the worthiness of this repair on an old vehicle is exactly the calculation I did before I started doing some body and frame restoration on my Subaru. While I agree with your overall assessment and this kind of work makes a lot more sense when you can do it yourself, you took non-road worthy car that wasn't worth much more than its scrap value and turned it back into a vehicle that can be operated safely and sold with a clean conscience. So you have added thousands back to the value of the car. This was my way of justifying the amount of time and money I've invested learning these skills.

[coolcat]

I just discovered a very similar situation on my 2004 Element. I immediately remembered this video and came to rewatch it. Replacing the vehicle isn’t an option right now and we love this Element so I want to fix it. Thank you Eric!

[tiberiusclaudiusnerogermanicis]

The cutting around the aerosol with a plasma cutter fail wad hilarious. Please include outtakes in all videos. Their hilarious. Nice repair as always eric

[Boilaroomnick]

I just bought an 07 Sierra that I have to repair one of the crossmembers and a small part of the frame on. These videos give inspiration and confidence to tackle something most people would shy away from, so thanks!

[chrisnorton]

Great repair Eric! I was thinking you might need a thicker plate around the bolt, but you boxed it in nicely. As an amateur fabricator myself, it looks good enough to me. I was especially impressed with your trick of bolting everything together to get a proper fitment. That was smart thinking. Some tips I learned from Mustie1's videos, is to now spray oil up into the newly fabbed piece, now that it's done. This helps prevent future rust. He uses bar and chain oil. I have used fluidfilm for this myself, inside doors I fixed.

I use pop and beer boxes for making my templates. They're always around and they come in different thicknesses. 👍

[stuckinmygarage]

I just watch Eric because he just connects so well. His attitude seems genuine. Simple truth.

[sirnik]

I just got done replacing bushings in my rear sub-frame. Oh, man, every time I watch one of your videos where your under a car I count myself lucky to be a California kid who doesn't have that level of rust to deal with :) But I really enjoy seeing you defeat that rust!!! WAY TO GO!

[mikeseymore]

I don't subscribe to many YouTubers. But it's people like you that makes knowledge power

[joemascioni]

I use cereal boxes for making my templates in metal fabrication. stiff enough to hold it's shape, but can still be cut with scissors. Besides, everyone has cereal boxes, and you don't need to go to Staples for manilla folders!...lol. Great video Eric!