1. Assessment and Planning:
* Extent of Damage: Thoroughly inspect *every* area of the Astro's body. Determine the extent of rust penetration. Surface rust is manageable; rust that's eaten through metal requires significant repair or replacement. Pay close attention to critical areas like:
* Unibody: The Astro's body is a unibody, meaning the body and frame are one piece. Rust in the unibody is extremely serious.
* Floor pans: These often rust badly due to exposure to water and road salt.
* Wheel wells: These are prone to rust accumulation from road spray.
* Rockers: The side panels below the doors are vulnerable.
* Door bottoms: Common rust areas.
* Frame rails (if applicable): While less common on Astros, serious frame rust compromises structural integrity.
* Parts Sourcing: You'll need replacement panels. Finding used parts in good condition is challenging, and new ones may be prohibitively expensive or unavailable. You might need to consider fabrication if you can't find the correct panels.
* Tools and Equipment: You'll need extensive tools including:
* Grinder with various discs (wire wheel, cut-off wheel, sanding discs): For removing rust and preparing the metal.
* Welding equipment (MIG welder is recommended): For welding replacement panels. This requires skill and practice.
* Metal shears or cutting wheel: To cut out rusted sections.
* Hammer and dolly: For shaping metal panels.
* Body filler: To smooth out uneven surfaces.
* Primer and paint: For protecting the repaired areas.
* Safety equipment: Welding gloves, mask, eye protection.
2. Rust Removal and Repair:
* Sectioning: Carefully cut out all rusted sections, extending beyond visibly rusted areas to ensure you remove all compromised metal.
* Surface Preparation: Grind and clean the surrounding metal to bare, sound metal.
* Replacement Panels: Install new or used replacement panels. This involves precise fitting and welding. Improper welding will weaken the structure.
* Welding: This is a critical step. Inaccurate welds will compromise structural integrity and lead to future rust issues. If you're not experienced in welding, it's best to seek professional help.
* Bodywork: Use body filler to smooth out any uneven surfaces after welding and panel installation.
3. Finishing:
* Primer: Apply a rust-inhibiting primer to protect the bare metal.
* Paint: Apply several coats of paint, matching your Astro's original color.
Important Considerations:
* Professional Help: Unless you have extensive experience in auto body repair and welding, you should consider seeking professional help. This is a very labor-intensive and complex job.
* Cost: The cost of parts, materials, and potentially professional labor could easily exceed the value of the vehicle.
* Structural Integrity: Compromised structural integrity due to rust is a serious safety concern. If the rust damage is extensive, the vehicle may not be safe to drive, even after repairs.
In summary, while it's *possible* to repair this level of rust, it's extremely challenging and often impractical. Carefully weigh the cost, time, and safety implications before proceeding. A thorough assessment by a qualified mechanic is highly recommended to determine if the repair is even feasible. They can provide a realistic estimate of the cost and complexity involved. You might find it more sensible to sell the Astro for parts or scrap and find a replacement vehicle.
