An exhaust leak resulted in this rust area on the rear lower bed panel. On the bottom it is pretty well rusted through. Overall the rest of the original body and paint is in good shape for it's age (92 Xtra cab).

Seems my most economical options would be to cut away the rusted sheet metal, spray with rust converter, bondo, prime and find matching paint. Since there will be nothing to really attach any fiberglass resin to after I cut away the damaged part, what should I use to attach the bondo? I understand I would be better with a sheet metal welded replacement, but I do not have access to a welder.

Recently found this site, wish I had found it sooner!

 

they sell some pretty thick sheet aluminum flashing that you could glue with seam sealer and pop rivet in place then bondo it after the glue sets.

 

cut out any rusty metal, then put fairly thin sheet metal, and epoxy it in place.
you can cut it so as to make it bendable to the general shape you need. It doesent have to cover 100%, but should be a good solid backing for the fiberglass.

then put long strand fiberglass over that, and a thin coat of bondo over the top of that.

 

You know what I discovered in my recent repair of rust? They sell some pretty decent little welder kits at Home Depot for $40!! Heck, I even saw them at Walmart the other day. In my repair, I borrowed my uncle's, but I'm planning on buying one of those kits. You can get disposable 02 & acetylene tanks for $7 when you run out. If you don't do that, I would also suggest riveting the metal on there, but definitely cut out the rust and add new sheet metal.

 

I used some metal mesh to mold the part and then bondo'd over it. Worked pretty well, but it requires a few bondo applications.

 

Thanks for all the responses.

I like the idea of sheet metal replacement as it is more permanent and the truck still has alot of life left.

Regarding one of these welder kits... how proficient do I need my welding skills to be? I have not picked up an (arc) welder since high school back in the 80's and back then I sucked at welding. I just played around with it, no formal training at all. Not familiar with Tig, Mig, just arch.

 

Well I would say you don't have to be good at it. being you are doing it yourself, who is going to see it. If it is lumpy of a wels, just grind it down to a smooth finishing. O, and by the way, the little kits from H. Depot are really cool.

 

Well I cut away the rusted parts and ground down the rest of the rust as well as I reasonably could. Will spray with rust converter, then I will try the Home Depot weld kit with some sheet metal.

If it turns out like crap this thread will disappear into the archives. If it turns out okay I will post a picture to follow up.

I googled Paintscratch.com looking for the original paint color in a spray can. Any other similar recommendations?

 

I doubt you'll be able to get the curve right. just try to get it close, but leave some space, and use bondo ontop of that. the bondo can be carefully sanded to better match the correct shape

 

Right, and check out my thread for some visuals that may be helpful: https://www.yotatech.com/forums/f116...partii-125973/

Good luck man!