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92 XFI project; I hope to make this baby look SWEET!
Topic Started: May 9 2010, 10:17 PM (809 Views)
GeoStalker
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"Chicks dig me and guys think I'm cool."

As mentioned in an INTRODUCTION post I picked up a 92 XFI a few weeks ago and immediately disassembled it. It needed some body work and rocker repair, and a frame stand welded a bit, but the car does run. I picked the car up for $300 and hope to keep any additional costs below $500.

First, a video. I got into the practice of taking videos of all cars I purchase for rehab, just in case the body is too far gone and I need to sell the engine, but also so I can document before and after. Here's a Youtube video from that day;

Youtube video of 92 XFI

Next, here are a few still shots of some of the major problem areas;

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.....rocker rust and door cancer.

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I started to tear out the filthy interior.....

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Floorboards aren't bad on the passenger side, just some surface rust from wet carpet.

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The driver's side floorboard is another story. It has a hole that I'll need to repair, but not a major issue.

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Got everything out of the car and just piled it in a heap for now!

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The first phase of the rehab is complete.......total disassembly and assessment. Now, the rocker repair work begins. I removed both doors for better access, and filled what remains of the rusted rockers with Great Stuff foam. This is so I have a form to shape the sheet metal around. Once I shaved it down smooth, I hit it with some rubber sealant spray. The picture you see here is the passenger rocker with the sheet metal ready to be formed to it.

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I then screwed the sheet metal onto the top of the rocker after a failed attempt at using JB Weld. Once secure up top, I wrapped the sheet metal around the rocker, and drilled screws into the bottom as well. The form came out looking pretty good. Once secure, I sprayed more Great Stuff foam into the gaps between the old rocker and the new. Once it hardens, it will make the rocker firm as to avoid denting.

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Now the driver's side rocker......

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It's gonna be tough banging out the dent by the gas cap, so after a few failed attempts I decided to build it up with sheet metal and bondo. Here's what it looked like before and after my first attempt at securing some sheet metal.

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That's pretty much where I left it for the night. More work to come this week. With any luck my paint will arrive by Wednesday and I could possibly have the car finished by Sunday. SFIEND was thinking about driving down from Lima, OH on Saturday for a little welding, so maybe he'll help me complete the project. More pics to come.

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Bad Bent
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Facetious Educated Donkey

Great video. ^o)

I admire your will to restore a Geo in need of some love. :thumb
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GeoStalker
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"Chicks dig me and guys think I'm cool."

After some rocker repair, bondo and paint, the 92XFI now looks like this......

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I put the repaired doors back on the car but forgot to take pictures before this posting. I hope to do that by this weekend.
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BraveHeartCalif
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You have the same smurf blue color as my 93 XFI...Ive been throwing around the idea of painting mine that white pearlized color you see on the newer caddilacs. But ill have to paint the inside on the exposed body part areas....Anyways keep up the good work!
Edited by BraveHeartCalif, May 29 2010, 12:47 AM.
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