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
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The best place for answers to your automotive questions: www.ericthecarg...
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Tools (some are affiliate links)
Body Saw: www.jbtools.co...
Plasma Cutter: www.longevity-...
Welder: www.longevity-...
Magnet Holders: amzn.to/3ud0QgD
Drill: www.milwaukeet...
Drill center punch: www.jbtools.co...
Stepped Drill Bits: www.jbtools.co...
Eastwood Chassis Black Paint: www.eastwood.c...
Eastwood Internal Frame Coating: www.eastwood.c...
Eastwood Rust Encapsulator: www.eastwood.c...
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.

[@ZuhScare]

I’m 17 too & I just started watching yesterday lol, hope to become a technician too

[@panzerveps]

I also found Eric about 10 years ago, while working as an apprentice. He's one of the reasons I passed my final exam.

[@ericthecarguy]

I'm truly honored by your comment. When I started ETCG I had hoped my videos would help people. I never expected them to inspire others like you. Thank you very much for that comment and good luck with your career.

[@theroyalcrownedtiger2946]

Hello Eric, I started to watch your videos in either 2010 or 2011, it's now 2022, and your videos have been extremely helpful. I worked in auto service garages before, and currently I work on my own cars, as well as for family and friends. With Much Thanks to you and your videos.

[@corydriver7634]

@@theroyalcrownedtiger2946 you’ve traveled ahead in time, how are things in 2022? Did we concur COVID?

[@toddcott9510]

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

[@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

[@ericthecarguy]

I do post out takes when I have them. I normally put them at the end like I did with that one. Thanks for the comment.

[@tiberiusclaudiusnerogermanicis]

@@ericthecarguy ah I don't always see the very end then. I will have to make sure I do that. I've been watching your videos almost weekly since your old garage. You taught me how to do an oil change. Must've been near 10 years ago now.. anyways still enjoying the content.

[@SalandFindles]

They're** hilarious, you're right.

[@tiberiusclaudiusnerogermanicis]

@@SalandFindles you must be fun at parties 🥳🎉

[@jusrobington]

Not one of Eric's smartest moments. Still glad you included it in the outtakes. 👍🏾 Good job man.

[@Gmacc187]

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.

[@sirnik84]

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!

[@dans_Learning_Curve]

Yes, our vehicles rust out before they're worn out in the rust belt!

[@pliedtka]

I couldn't believe some of the cars in California - 30yrs+ old car and no spot of rust. I envy my sis.

[@tiko4621]

@@pliedtka I work as a lube tech for a local place here in the Bay Area, 30+ year old cars VERY RARELY have rust on them here.

[@HUBBABUBBADOOPYDOOP]

This reminds me of exactly what I had to do to my '89 Buick, when I replaced the transmission. One jerk in the Club I belonged to at the time- remarked it would be labeled scrap where he came from, and he was very nasty and rude, something about "polishing a _ _ _ _". He's a big deal Moderator now, 10 years later- go figure? Eric, you did a wonderful job here. Always remember- because the temper is changed, a weld is always the first to rust. Keep welds to a minimum, and treat them accordingly. You could've made a "box" and made folds on a pattern, 2 welds. Easier with a bender. The threads are deep, so the shank goes up into the mount, more integrity, less wiggle as possible. That's what the busing is for, giving movement. A wiggling bolt would snap. The 4 bolts I had to buy were $30 each. Bushings were $50 each, got all 4 for rear of front cradle.

[@rotor13]

I mean it’s an 89 Buick. He’s not wrong lol

[@pthomas36]

I'm watching a lot of these videos right now because I'm working on the frame of my old 05 4Runner. Thanks for the inspiration and insight into the work I have ahead of me. Time to go turn on the gas for my welder...

[@mikeseymore2548]

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

[@austin7082]

Watching your videos all these years have slowly made me distrust technicians, seeing you go way out of your way to fix the super small details that would turn into big problems down the road. There’s no way for me to make sure my mechanic is catching those type of things for me while he’s working. I highly admire your work ethic and I wish there were more like you.

[@ericthecarguy]

Thank you. I actually made a video on that topic last week. kzbin.info/www/bejne/mIPQm3ymq6iarc0

[@joshkjohnson]

Looks like a solid repair. I liked your approach to fixing (I'm not a welder).

[@vdog4799]

I hear that. Me neither. I bought a HF welder and have beenmplaying with it. Its pretty cool

[@Bot.number.69420]

Also elements rust from lower rear trailing arm front mount I heard. So glad I keep mine treated with rust prevention. That kind of repair is borderline illegal here in Finland and they get angry at yearly inspections. :/

[@evilstan60]

No states truly do a safety inspection here. It's basically checking if tires and brakes are good. No body shop would do this repair here though. That frame rail is high strength steel. Welding in mild sheet steel changed the crash characteristics of that frame rail. Granted, it's far from crumple zones and would likely not be an issue, but still not something a body shop would touch with a 10 foot pole.

[@rolfbjorn9937]

@@evilstan60 Fairly sure that old and degraded High Strength Steel, due to heavy corrosion, metal fatigue, probably micro fractures all over the place, or even prior repairs where someone used a torch to loosen fasteners...no longer qualifies as HSS and that brand new thicker guage low-medium carbon steel has better properties.

[@e.e9331]

cars turning into rusty piece of shit in less than 8 years is a normal thing in Canada especially in Quebec so body jobs are a common occurence here, most shops wouldnt do repairs like this but this is 100x prefered over its previous condition in which probably millions of canadians drive around in. waht do you do with a car in finland thats around 10 years old and has market value of around 20-25k$?

[@Bot.number.69420]

@@e.e9331 some cars get anticorrosion treated here regularly or expensive ones at import to give more life. Most cars have little to no value at 10 years and get scrapped after rusting too much. Cars lose value really fast here. I just scrapped 2005 Hyundai because not paying 3k€ for new subframes and they can't be welded. We had demolition campaing (for new ebike, car or train tickets etc) and cat prices are high, cheap cars have gotten crushed away. I got 1000€ from crushing that hyundai towards my new ebike. I did find well treated 2005 diesel crv with abs problems for 2000€ couple years ago so driving that, after swapping usa/germany spec abs sensors, cause it's 200-400€ cheaper per month to drive than element.

[@abea4696]

Your videos have been my favorite for over 10 years

[@davidg5704]

Cavity wax in the end to fill those gaps. Awesome job. I need to break out my new welder and do some repairs. Thanks for the video.

[@jacoblloyd2573]

What an advanced understanding of metal and of the complex machines that cars are

[@roddydykes7053]

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

[@fflynnful]

Bondo and pop rivet rust repairs are less expensive. This video shows how it is done properly resulting in a safe vehicle.

[@BlazingLightSword]

He did that repair in 25 minutes though, that shouldn’t cost $3k+! /s

[@dans_Learning_Curve]

@@BlazingLightSword the repair was condensed to a 20 minute video. I'm sure he has more time in it than that! As he stated, he's not a welder or fabricator. Plus he took the time to video it. Setting up for video takes time. For a beginner, like me, he did an excellent job!

[@1nvisible1]

*A cast sleeve in a welded mount under a stamped raised ROUND footing. I don't know a lot of guys that would've fabbed that from scratch, especially with only three tools. Good stuff.*

[@TaintedMojo]

@@BlazingLightSword you actually thought that took 25 minutes? SERIOUSLY?

[@johngoepel5263]

Super informative, thanks! Also way to almost get Jay Leno'd with that plasma cutter lol. Don't plasma cut against an aerosol can kids!

[@jacobaguilar6756]

You've actually helped me out of bad funk ive been in showing it's okay to make mistakes and that it's all fun and learning thankyou tons!!!!!

[@Tjousk]

I have recently complained on another video about the way they display ads. Keep being you. I've not yet seen one in this video, but from past experience you make it clear when something is an ad, or sponsored, or something similar. I know this doesn't fit in your comments, because you're not annoying in this way, but I just felt the need to say thank you. You are on of very few left that still make me want to stay on this platform.

[@ericthecarguy]

FYI I normally post sponsored content on Wednesdays, regular repair videos on Fridays, and ETCG1 videos on Mondays. Also as you stated, I clearly mark all sponsored content to avoid confusion. If you don't see **Sponsored Video with great information** above the fold in the description, it's not sponsored content. Thanks for the comment.

[@Tjousk]

@@ericthecarguy Indeed, to be clear, you make such things clear... I want to thank you for doing so. Keep up the good work.

[@nicmo6913]

Thanks Eric I found out that mine has the same issue yesterday and come search for your video.

[@johngoudie6676]

Great job Eric! I have to do this on my 06 Sienna, so the timing was perfect!👍

[@matthewnobles7533]

Nice work Eric! Back when I had my automotive shops this is what I would specialize in in upstate New York. Frame repair body mounts even control arm brackets built in the subframe that were rotted. where a lot of other shops would not even touch it or even think about saving a good vehicle. Sometimes it is a lot of work. It's mostly pickup trucks but a lot of cars also. It's got to be my favorite video I seen from so far because this is what I used to specialize in. And I still do it on the side. And then there's always that argument whoever is inspecting the car especially dealerships oh that's been repaired we can't pass that b*******! That welded in bushing your repairing it's going to be stronger than the whole support.

[@mochamartian3189]

Do you recommend anybody in Upstate NY nowadays? I’ve got a 03 TJ that I want to save… what the last owner did will shock you.

[@chrisharris3371]

I love the video and the how to nature of the repair process. I am repairing my truck but this process will work for me. Thanks!

[@johnnym4220]

That's a repair to be proud of my friend. 👍

[@jeffjackson8381]

For not being a fabricater you done a cracking job

[@sandy7m]

I used to finish off my under- side patches with thick layers of paint then warm bitumen glue applied with a paint scraper. Durable and makes the welding look a bit neater :-)

[@donald4416]

Eric , Applause 👏 fantastic job Hey just Note back too you I'm repairing my Dodge truck bed Do to fact that I don't have 1500.00 + to buy replacement bed So I'm fixing mine to extent of all rust gone and making tilt bed also. So keep up those videos it gets message out well thanks Donald

[@dillwizard7516]

Very helpful. I have a 94 GMC K1500 and it has two "you should really look for a new vehicle" spots. They are however repairable. Thank you for the insight.

[@timmypstyle]

I NEED this. My 06 monte carlo is succumbing to structural rust. has 92k miles on it. Got it 4 years ago with 61k and a fresh PA inspection. 😢

[@bneyens]

I always thought that if your frame was rusted like that, the car was done. Good to know it CAN be done.

[@ericthecarguy]

Given that this would likely cost in the $3-4K range to repair, and these Pilots are only worth about that much, you're better off getting rid of it unless you, or someone you know, can repair it. But yes, it can be done.

[@gerrytseng]

that end blooper was EPIC

[@petemoss8625]

Nice work Eric, always satisfying doing this type of repair. Cheers from the UK.

[@Stop..carry-on]

Your welding has improved

[@ericthecarguy]

Thanks. Practicing helps a lot.

[@mr.nobody6457]

Wow! Eric has some skills!

[@thisismyalt9010]

Oil spray keeps the rust away. Thanks for the vid.

[@endeavour2127]

Good solid work! I thought you might have tried to recreate the dome to make it look more oem but this still works. 👍

[@mdrew44628]

If you sell this vehicle at some point, the buyer will never fully appreciate the work you put in to restoring the vehicle.

[@Northernstar9370]

Superb video Eric! I'm going to be doing a similar unibody repair on my 2010 Ford Escape. This gave me some great insight on the plan. By the way, I've been watching since you started years ago and your technique and quality is as great as always! Thank you!

[@markpoxton1119]

mint, love a bit of patchwork welding :)

[@paulsmith9341]

Your hammering at 18:00 sounds like Mary Had a Little Lamb.

[@cocosloan3748]

Hard job -executed properly - solid material - will last next 25y at least !

[@paulwright3261]

Amazing techniques, and workmanship Eric! You dah man!

[@The_R-n-I_Guy]

I need to make the same repairs on my wife's 04 Pilot. I'm thinking of getting heavy gauge plate and just boxing in the entire area after cutting out and treating the rust.

[@xxxxxxxxy11]

Soooo much creative welding. And nice work. Why not cut out the section ? Cut and weld in a refurbished donor section ?

[@DoctorSherwood]

nicely done eric

[@steveafanador6441]

Man I thought you were gonna play a little song there tapping that steel 😀😀👍😀

[@Dratchev241]

he was playing the song of his people.

[@steveafanador6441]

@@Dratchev241 exactly 😀👍👍

[@grindersandgears3445]

Definitely a lot of work in a repair like that, looks good. Little bit jealous of the plasma cutter, gotta get me one of those. Had to patch the frame on my Suburban and it was no easy feat, as I don't claim to be a pro at welding/bodywork or fabrication either. Did mine pretty similarly method wise, had to cut off one of the swaybar mounts bc it was rotting out too, re-connected it to get the location to weld it back in place after patching where it mounted to, and lastly used a similar solution to prevent future rust, but the stuff I got was an oil based coating, had the same hose and nozzle bit though to get inside, just used rustoleum on the outside. I'll probably get that Eastwood stuff next time as it looks like a more permanent solution.

[@wobbiewall4821]

Very nice. Missed a plasma cutter last week. Gotta try harder.

[@kevinritchie9227]

Very impressive. Anyone (with the right tools) could do that if you take your time.

[@waiting4aliens]

16.43 recheck, brilliant

[@darrinrentruc6614]

Do you realize how close you came to blowing your face apart with that paint can? Thanks for showing that. I had a friend who's dad [a well seasoned mechanic] was working on his boat engine when the can off starter fluid he had set on the battery fell over and some how hit the positive post and a ground point at the same time and exploded killing him a couple days later from injuries. Be careful with the cans out there guys.

[@mattrimmel9165]

I am from PA this is just a day to day repair for us

[@YT-User1013]

Tape off the other holes when treating the inside with Eastwood. FYI, I've seen tests that show that this Eastwood frame treatment is not really as good as as they claim and the old-time frame treatments are hard to beat (like Fluid Film and even better is the newer product Surface Shield Blaster).

[@falcon6415]

Nice work your a true craftsman !

[@callmenortnortin467]

Nice repair Eric. Enjoyed watching this lesson

[@markahad6583]

Awesome job Eric 👍

[@RESTORATIONRESCUE]

Great video as usual. I always learn a lot watching your videos!! Definitely helped with my own videos.

[@clovisabdiasdasilva683]

Wonderful repar, I liked very much.

[@xandriasmall6668]

this video would have been extreamly helpful about 3 weeks ago when i fixed my sisters pilot. the rust was only one one side and not as bad so i just formed a plate and welded it on top. i didn't completely drop the sub frame. had to weld in a mirror though.

[@clovisabdiasdasilva683]

Beautiful job. I liked very much

[@Александр-б8з3о]

Круто! Руки из правильного места растут!

[@bsd7342]

I've seen them where the bolt and subframe drop out of the beam and are dangling. This one still looks rigid. If there wasn't any play, I think it would've been easier to just wirebrush all the rust off and reinforce the existing plate with more welds inside the cavity space. Maybe even add some jb weld to the cavity, it would reinforce the missing metal and possibly be better than the eastwood at protecting this high risk area from future rust.

[@pliedtka]

Ah, we love the rust in Snow Belt. I love lots grease and rustproofing in those corners underneath cars I work on. Saves me so much grieve with bolts that snap even when heated and rusty holes. F...n snapped Odyssey K-frame bolts and frame cutting to get them out ... 🤬🤮

[@ludditetechnologies]

Awesome repair man.

[@formula1vhr]

Had to junk a 2003 Pilot last year for the exact problem. 290k miles.

[@Not.Your.Ordinary.Garage]

Ericthecarguy please do another tool box tour like and update since you got all new tools from gear wrench if you got time for a video be pretty cool to see a toolbox tour with what you have all gathered since the last one with your snap on box

[@jaredjansen4236]

I've watched your videos for a few years and they have always been very informative. My only question is why didn't you use weld threw primer?

[@McTroyd]

Right now, the price of a new (or even new-to-me) car in my area is prohibitively expensive. Rust repair might make sense. Besides, even if you bought another 2003 Honda Pilot, even without this issue, what other issues might come with it ~19 years into its service life? Thanks for the info in any case -- I've never seen this done, and it does help explain the expense. 👍

[@jesperdahl1486]

The word you were looking for was "carton" the stuff cereal boxes are made from, and phone books covers LOL

[@Hello-pl2qe]

Nice job, that looks good.

[@tiredhub3270]

brilliant job

[@charleswright5989]

Hi Eric don't weld out joints just tack every 1", when you weld out a joint it causes stress and will Crack again right next to the weld because the weld molecules are not aligned with the material the only way to prevent it from cracking when you completely weld out a joint is to stress relive it with heat you have to heat the material up to 1100 f. For 10hrs. That realine the molecules making it one just tack and epoxy

[@JOEZEP54]

Hi Eric been awhile. Nice repair. I may be doing something similar soon. Another 👍added, Stay well, Joe Z

[@Therealjimjam]

Dude, I judt love your videos lol. That was really cool.

[@Enrique2k52]

Like always excellent video thank you!!!

[@AhitagniDasgupta]

Great work as always :)

[@o11271978]

I had to replace all the interior metal barrier of the rear bumper was all gone by rust.2007 honda pilot

[@crash0799]

nice job, seems to be structurally sound so I call it a win. body repair is a hole different animal from regular auto repair lol. check out weld through primer, spray on the back of the panels let dry then weld in place. it was designed for bodywork, wont catch on fire when you weld it.

[@grilledepoxy8658]

very good job

[@armelind]

at 6:15 I have seen other youtube autobody fabricators use old Cereal Boxes as their CAD templates. (Cardboard Aided Design)

[@havoc9926]

Nice work.

[@biff1tannen]

Very fine video 😊👍

[@deangeorge4982]

Nice.

[@Blutnase]

Guy says he's not a master fabricator or the world's best welder, but you know you're going to be schooled. A good vehicle is more worth being whole than being parted nowadays.

[@jb_bmwrepairlyfe4704]

Is the car worth it? Probably not! But for the pleasure of just thinking that you’ve created a whole new piece that you cannot buy at the parts store, absolutely!

[@roccosarli6939]

What would the cost be to have this done.

[@stco2426]

Excellent!

[@mechantics]

Hey Eric, do you have any thoughts on the use of Cosmoline in preventing corrosion? I first heard about it from a friend of mine who began his mechanical career on the line of VW's factory service in the 90's (he should write a book about the day to day absurdity that drove him and a colleague 30 years his senior to open their own 2 bay shop).... the first time hearing the name 'Cosmoline' was when he described the grueling task of removing broken glass from the gunk that VW coated the inner door panels with. His overall judgement was that, when used properly, it lives up to it's reputation as a military grade anti corrosion coating*, though VW basically just created water basins out of the doors due to poorly sealed windows and inadequate drainage and a lack of attention to coating the innermost portions of the doors, presumably the most rust prone areas *(apparently it was first trademarked in the 1860's or '70's as a topical agent for anything from puncture wounds to dermatitis, not to mention the horse's hooves!) I'm attacking the cab mounts on my '67 Dodge d200 Sweptline, and figured you might have some valuable insight into pros/cons, limitations and alternative/additional products to consider in my quest, as Biden might say, to "Build Back Better"🦾👀 Thanks for the awesome videos!!

[@afeeqahalwi9074]

Eric TheCarGuy

[@piwex69]

Bracketry level the Project Binky.

[@3DPeter]

i restore oldtimers, so there's always some welding involved and some even need a ton of work and i hate it because it's time consuming and a dirty job, and not to mention al the splatter of hot drops of metal that burned more spots on my body than the moon hs craters, because there are always areas that are a little rusted but you can't get to it to clean it, and then the fireworks begin.

[@charleshoops2307]

one question Eric is that cross member high strength steel. If so is it weldable under repair weld conditions>

[@throttlebottle5906]

I wonder what would happen if someone was to closed cell spray foam a vehicle full, instead of open areas and voids in the unibody, obviously not door/windows/moving parts. I guess one downside would be material to burn and emit toxic fumes if in a fire.

[@henryphiri4653]

Bro last time you posted a video talking about crankshaft thrust bearings...how about if the car doesnt have them completely,will it still move nicely??

[@randellgribben9772]

....................CAD design .... cardboard aided design..i use it all the time also you can NEVER have enough sharpies around when you are doing this kind of work... also a question.. are you going to add a couple water drain holes. for any water to drain out of? and spray some paint inside to keep any rust from starting?

[@christopherthumm4348]

I'm curious what you would charge for a job like this ware there is not a lot of material cost but a lot of labor .

[@danielbooth1878]

Cracking job

[@pwee507]

17:30 Eric plays us a tune

[@pwee507]

18:53 play it again, Eric

[@MrCdrant]

You want to use oil board for templates.

[@rohankansagara848]

Omg the ending 😂😅

[@brentfrederick6576]

You did a great job next time you used weldable primer on the inside so that the interior metal that you've welded inside your opening is primered so that it won't rest again