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So my “project” cheap Cobalt had a bit of a surprise this weekend… I got the car for $1000.00 CDN.. 2006 Cobalt LS. It was in what was apparently a minor front end collision and had a G5 front bumper and a different hood..

The hood, bumper and headlights were not lining up properly and I decided to find out why… Well the front frame rail / bumper support (same frame rail that the horn and washer bottle attaches to) was crushed! FAK!

So I cut the frame rail with a sawzall and a good blade. I took some measurements and cut one off a Cobalt at the junk yard that had a good front end.

After several measurements, some fine cutting with a cut off wheel, I tacked on the replacement frame rail. Test fit everything, took everything off and then welded the frame rail properly. Looks much better and is pretty solid!
 

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Yeah pictures are always good!
 
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