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Rust Repair by a first timer :D (warning: big pics)

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Old 05-17-2009, 08:16 PM   #1
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Rust Repair by a first timer :D (warning: big pics)

I've never done bodywork or rust repair on anything, just mechanical things. My truck had what has to be one of the worst rust repair jobs ever, on the corner of the wheel well. It was a piece of carpet, with bondo on it and painted over, and expansion foam filling the wheel well..... I'm no bodywork genius, but that was a nasty "repair". So I cut the whole piece out and welded in a piece I fabbed up. It was a tricky bend, since it had about 5 different directions to follow. Its not perfect yet, I still need to fill a few spots in the joint with weld and grind it smooth, but its nearly there. No rust, decent looks, what more can you ask for on a wheeler.









Side note: I need some advice on my middle body mounts (the ones right below the door hinge). There completey useless, like the floor pan is sitting on the frame in that spot. The mounts are loose from the body. Any tips on getting some new metal in for them?
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Old 05-17-2009, 08:24 PM   #2
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Nice work!!
I would like to see a pic of your flatbed!
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Old 05-20-2009, 05:15 PM   #3
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Was bored just now, so I got up on this small rock. Mainly to test my front brake line length, but you can see the flatbed in the pics.


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Old 05-20-2009, 05:20 PM   #4
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niice yota man!! and good repair.. im pretty much rebuild a suzuki samurai Long wheel based from scratch !!!
i like seeing welding!
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Old 05-21-2009, 06:22 AM   #5
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Turned out pretty nice. I dont think I care much for the foam in it, but the overall look turned out excellent. Great job. Did you get ALL teh rust off of the inner fenderwell before you closed/sprayed/painted it up? IF not, that new paint won't last too long.
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Old 05-21-2009, 10:41 AM   #6
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I took all the foam out. The prior repair was what used that foam. What I did was wire wheeled all the buildup on the inside, then cleaned it with acetone, and put two layers of rust paint on for now, until I get all the rust repair done. I'm gonna paint the whole cab silver or something later.

My middle body mounts are completely rusted off, I need to figure out the best way to weld in some new metal there to support the cab. It's basically resting on the frame there.
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Old 05-21-2009, 11:25 AM   #7
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GREAT REPAIR!!
That is a great looking truck.
I am in the process of designing a flatbed for my 94. Thanks for the photo of that.
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