Auto body repair & detailing: Taurus unibody repair, wheel drive vehicles, spot welds

Question
My 1991 Ford Taurus needs repair of the rear strut towers with rust damage. Is this practical and what is the procedure?

Answer
Hi Arline!....Depending on the severety of the rust, this would be the worst case senerio....Replacement of the complete strut towers....As this is a safety issue....To do this, first of all, the complete rear suspension will need to be removed....Next, you need to make a scribe line around the strut towers where they were installed from the factory....That way, you can re-install the replacement ones in the exact position, or as close as possible....You will then need to drill out the original spot welds....In my experience, using a rotobroach, will give you the best results....A 3/8 inch one is required....Once this is done, the towers can be removed....You will then need to duplicate the amount and positions of the spot welds, and weld the replacement towers into place....Next, I would suggest dressing the welds, and applying corrosion protection...This protection, is available in a spray can, and is high in Zinc...This will protect it from further rusting....Next, you can simply apply an undercoating....Also available in a spray can....The last step, would be replacement of the suspension....After that is completed, you will then need to get a 4 wheel Thrust alignment....Most front wheel drive vehicles made today, have an adjustment for camber on the rear struts....Some also have a toe adjustment...This will eliminate a dog tracking effect....If you would like me to explain anything I have mentioned to you in further detail, please drop me another line...I would be more than happy to help you out...Thanks...Dave