FF1_69

The spray gun that I used cost about $50 Aust. The brand was Wagner I think. I also bought an accessory 5ft extension complete with the 360° nozzle. It could handle some pretty thick stuff but I had to play with the viscoscity with more or less solvent and adjusting the stroke length until I got the right spray pattern. I would rustproof before I'd attempt filling those cavities with chassis foam. You would lose all access after. It's messy and be prepared with lots of little tins to catch all the drips or put up with a messy driveway. Michael

Like Subaru360 said, using a hose with a special nozzle fitted, you drill a hole to suit the size at the end of the sill so that the hose or a flexible wand with nozzle attached is inserted, pushed all the way up and spray the product as you withdraw the hose at the required rate to ensure that all the surfaces are nicely coated. Your nozzle should have a nice 360° spray patern. I used an electric spray gun to apply the Valvoline Tectyl/Fisholene mix. Worked a treat. Michael

As long as all that new steel and the rest of the car is rust proofed it will last, but leave it bare inside those new sills and you'll have another rust bucket in under 2 years. And it's easyest done when the car is just a shell, then you can get into all those cavities, nooks and crannies. Michael

First post for this thread. God this is so close to home. In 1970 I bought my FF1, a White 1969 2 door 1100cc sedan. Just like this one, only much, much younger. Had it for 3 years and put 87,000 miles on it. Still the best of all the Subarus I've had. Even better then my last, a Legacy AWD 2.2L GL wagon with air suspension. I should have kept it, you don't realise the treasure you have until it's gone. And I miss it. I know where there are 3, a 2 door and a 4 door sedan and a 5 door wagon. I don't think the one owner wants to part with them though. I hope this project fulfills your expectations completly. Best wishes. Michael