OldSub,
Send a couple pictures of the rust areas. They can be repaired with a combination of light welding (put your white doctors coat on and one of those old doctor caps with the big reflectors on it LOL!)for some surgical repair.
I use a product called Belzona along with small spot welded metal patches (to hold them in place) to close in the area. The Belzona is a metal adhesive / metal filler polymer used in industrial applications to repair bearing cups, bushings, and other areas where welding is not a practical solution. It is machineable and is a very good high end professioanl product for a number of applications. Complete the repair with some light grinding and smoothing and the repair will be invisible and strong. I have used it for some enlarged bushing holes on the frame. It comes with a release agent. Apply the belzona within the bushing hole, then insert the bushing with the release agent on it. Move it around as it cures and let the Belzona harden then pull the bushing out and the hole will be a perfect fit for the bushing. It will last and last. If it is too tigh a light honing will get it just right.
Check out the Belzona website, it can be molded to a contour before it hardens and provides structural strength. You will need to visit a large machine shop and see if they can order it for you through them. Belzona will only sell to industrial consumers (not retail to the general product). It's about 175.00 for a kit, but it will go a long long long way to repair small rusted areas, pin hole repairs on sheet metal, bushings, and again, when hardened, it will add to the structure of the metal. It does not absorb moisture or shrink over time unlike polyester and glass based fillers etc. This is a huge step up from the Metal to Metal, JB Weld, and other products too.
I have used it on cowl reapirs, small rust area dooor pillars, etc. I do not need to cut out and patch. But I do remove the rust and thin areas and go through a rust removal process using some of the zinc phosphate based neutralizers like POR15's Metal Ready.
I grind and sand it flush and just before it hardens fully, and still has some elasticity a wet finger will form it to the contour.
I have one extra pair of the rear window interior trim pieces. They need some light repair work. But if someone wants to purchase these at a fair price e-mail me at
[email protected] I don't need them. I do not have the center section pieces though just the rear window trim.
Just out of curiosity, what would a new upholstered AD suburban rear seat sell for? Anyone know the value of one?