rust is winning! Help!
 

Hey everyone, i need advice. I have a 97 LS 4wd with 120k that's awesome except for a bad rust issue. I live in Denver but he (Green Goblin ) comes from Minnesota and you can tell. I bought him about 3 months ago and i've already put a lot of work in with a ton more i want to. How much is too much, what are my options? This forum has always been there for me, shout out to Capt Hook! The ignition switch works perfectly but now i just want to know if i can save him...

I should add that I've definitely tried checking for other threads but none answered my question. If I missed one, please let me know!

That all just looks like surface rust to me, nothing to be concerned about safety wise yet.

You could try wire-wheeling the rusty parts and then hitting them with a spray paint that is supposed to stop rust.

really? That's exactly what I was hoping! Here's a few more pictures, i also can't remove the plug to check the rear differential. At least i think it is. A 1/2 inch ratchet fits almost perfect but i think it's rusted on, i have tried as hard as i can without stripping it. is there a particular brand you know works well?

I just wire brushed and washed my frame, and then painted it with rustoleum black. So far it has held up great even through winter in MI.

All the frame parts are fine. The one body shot needs work but not bad

Nice, thanks for the info! If it works in MI it'll work down here. As for the body i think i just want to find new rocker panels. Those with some nerf bars would be better for the mountains, don't you? Any tips on getting the differential plug out? I sprayed it with bolt loosening spray 3 times in as many days and I still feel like I'm going to strip it. Is there a way to take the vent tube off the top and check/fill from there maybe? 120k and I'm pretty sure it's never been serviced...

For that plug you could try placing a chisel in the corner of the square hole and hitting it counterclockwise. If that don't get it I would remove the cover and change the gear lube. That way you know it's new. And while the cover is off you can drill out the check plug and use a bolt extractor. I'm also in MI. and have used por-15 rust coating for 2 years. I'm happy with the results. It's a bit pricey but worth it. Just follow the instructions and if it gets on your skin, it WONT come off.

I've also heard good things with the POR-15. If you want it done right, and have the money to do it, that stuff is really good. I thought it still had to be top coated though. It just stops the rust.