I got a lot of maintenance done today plus repair that was really irritating. Stuck around at the shop after I closed it to use one of the lifts to change the oil, lube, rotate tires and nut and bolt the suspension. I did find the right rear upper shock bolt backed off part way and a rubber isolator for one of the exhaust mounts disappeared. Nothing remarkable though.
The annoying item was the passenger front fender. The upper rear bolt and bolt in the door jamb have backed off in the past and the fender starts itching the door and rattling. Considering the condition of the trail I did on back to back weekends I'm not surprised anything came loose. But it really had been getting worse to the point the dang thing was itching with it parked and the engine idling. I've got a higher threshold for squeaks and rattles than some but this was beyond my normal that was acceptable. Not having a welder at my house I got a message out to Ian and he said to swing by on the way and we'll tackle it. I could make it itch by pushing in on the fender now and the door was rubbing the back edge of the fender as it opened. Checking the bolts that have come loose in the past found they were tight. Looking down on the top inside edge of the fender near the hinge we could see the spot welds from the outer skin to the inner support had popped. The panels had spread apart so we decided to pull the fender to be able to access the area better to clean up and weld.
This is the only non-GM sheet metal panel on the truck. Larry noticed this way back at the beginning but at least it was in one piece then. Pulling the fender exposed even more problems. The inner panel had a couple of major cracks coming down from the inner support that had broken free of the outer panel. The whole area was floppy and was the exact source of the itching noise I was hearing. You can see the cracks in the pic below. Stinking junk panel.
Ian was able to spot weld the outer panel to the inner in about 3x more spots than the Taiwanese aftermarket sheet metal worker did over there. We drilled out the end of the cracks and stacked tack welds to stitch it back together.
We found more cracks in other areas and one of the captured nuts for the battery tray to the fender broke out too. This fender is fubar and really just needs to be chucked but that isn't gonna happen before the trip. We muscled it back into position to line up the bolts and screwed it back together. There were no more itch/squeak noises at all. It don't make noise if you push on it or if the engine is idling. The ride home was silent. Thank goodness because 2500 miles or so of it making noise might have had me loose my mind.
Tomorrow I need to repair a wire that was pinched under the battery and install an external speaker for the Ham radio. The radio is great, but having to run with the windows open had me straining to hear it going down the road. I plugged in the speaker and set it on the dash and tuned into one of the weather stations on the way to work this morning. I could be going 70mph with a window down and the stereo fairly up and actually had to turn the Ham radio down it was so loud.
Other than some cleanup it's ready to start packing gear and getting the food together to cook for the week. I'm beyond ready to go mentally.