As a thank you for the advice I received on this forum, I though I would post some pictures of my strut tower repair I completed this week.
First a picture of the damaged towers. The holes were not this prevalent, but were typical "blistered" rust. We hammered them down so that the repair caps would fit correctly, and this is what was left after that process. The material that remains is fairly solid. I painted it with primer, not that it will slow any future rust by any appreciable amount, but I felt better!
I can't help but wonder what was keeping that left strut from coming right through the cowl whenever we went over a set of RR tracks!
The spots where the paint is ground away is in preparation for the welds. I did not buy the install kits, or the glue... but rather chose to weld them in since I have the equipment to do so.
Here is a picture of my brother in law, Mike... welding in the right side repair cap. The Miller mig welder worked great! The extra piece of flat iron you see the ground clamp on was tacked to the repair cap in order to get a good ground. It was of course removed after the cap was welded in place.
A picture of the cap after is was welded in...
... and after it was painted!
And the left side after the same process...
The caps came from my local Chrysler dealer. Total cost was about $30 a side, or less that $70 after tax.
The repair was fairly easy for me, after I figured out how to get the cowl assembly off (darn Haynes manual... nothing on removal in there) and no instructions came with the kit.
The van has 170,000 miles on it, but it still runs like new. That all being said, we will probably replace it before it get 200,000... so if the repair holds it together that long, I'll be happy.
Should anyone have any questions about this repair, I will be happy to share what I know. I will stay subscribed to this thread and answer any questions posted.