Stupid Rust

[rebelgregory]

So in getting ready for paint, I've been working on some prep. A couple dents, small rust repair patch on the passenger rocker, but I've been saving this one spot for last.

I had a feeling it was a little worse than I suspected. Sure enough. Cut way farther into it than I had planned on. Worst thing is it's in a pretty gnarly spot where the cab, drip rail, B-pillar, and bedside all come together. So many layers and contours. This is really gonna test my (rookie) fab skills. They don't make a patch for this.

So here's the plan so far:
It's cut back to good metal now but there's some surface rust on the interior layers. I'm gonna blast what I can and wire brush the rest and spray rust converter. Then I'll reapply seam sealer to where the quarter mates to the pillar and then where it mates to the cab. I'm gonna do my best to get the new metal into shape, but some filler is gonna be in order.

Anybody have any tips or see a flaw in the plan? I couldn't find anything comparable in the 'Body Shop'. Pics:

 

[rebelgregory]

Couple more:

 

[Stomis]

Take it in pieces. The bed side should be a separate piece given the seam sealer I would think.

The drip rail is the bitch.

 

[rebelgregory]

Yeah,I tried to plan ahead. I cut off 3 different pieces. The drip rail was intact, but is mated to the rusty pillar metal. I plan to patch in a new flat piece (easier) to the original drip rail so I can weld the original drip rail back where it goes.

 

[rebelgregory]

So I made some progress over the holidays. I've gotta say, I'm pretty happy with what I got done. All in all, I cut out 6 pieces, had to fab 3 of them to go back in. Only the drip rail remains, but I was able to separate the pillar piece from the factory drip rail, so I can just weld the original rail back in. Pics:

 

[rebelgregory]

More pics

 

[rebelgregory]

Last set:

 

[Blazer addict]

Last set:

Coming along nicely.

 

[kennyw]

I have those same magnets... still haven't used them after 10 years but I guess that is the price I pay for owning rust free sheet metal.

 

[rebelgregory]

They're a big help when you can't use the big vise-grip clamps. I used to think mine was rust-free until I stripped it down. There were only 3 rust spots and the total amount of rust could fit under my hand. But I want it all fixed properly, so I guess this is what I have to do.

It has been interesting. I'm a really good nut and bolt guy, but don't mess with thin sheet metal much.

Gratuitous pics of my 1 ton swap below. Just because I don't have a build thread and I think they came out nice.

 

[kennyw]

You guys get a little more snow and salt on the roads than we do up here, but thankfully nothing like the midwest uses. I do have one spot about the size of a quarter on the top of my drivers side rocker that is starting to rust. Looks like a spot that trapped dirt and water running off of the door seal.

 

[rebelgregory]

You guys get a little more snow and salt on the roads than we do up here...

Nah. I'm in central Alabama. It might snow once a year and the city has no salt equipment. They have spread sand once when a lot of rain iced over, but that's about it.

I grew up - and this truck came from - on the Gulf Coast. Lots of humidity all the time. I figure that was the culprit.

And yes, these trucks are masters of capturing water. Before I send her to paint, I'm gonna go bananas with the seam sealer on all the little nooks and crannies underneath.

 

[kennyw]

Nah. I'm in central Alabama.

I saw Utah in someone else's post and mixed it up with you.

 

[magik235]

Excellent results. I hate rust.

 

[rebelgregory]

Thanks man. Yeah, I really can't complain compared to some other trucks I've seen on here. But after going through the effort to totally de-rust a vehicle, rust will be a big no-no on any future vehicle I buy.

 

[Chief Brody]

Thanks man. Yeah, I really can't complain compared to some other trucks I've seen on here. But after going through the effort to totally de-rust a vehicle, rust will be a big no-no on any future vehicle I buy.

awww...come on...you know it's fun...

even the California ones have rust...somewhere...sometimes it's fairly bad too...

 

[rebelgregory]

About as fun as crapping a pine cone.

I bought this truck in 2000 and it was truly rust-free. In fact, you could still see grease pencil markings on the underside from the factory. Most of the rust I had to fix was the result of little pockets of mud that I never cleaned out. Every time they got wet, they would just hold water. When all this is said and done, I don't think it'll be in the mud again for awhile.

Big fan of your build btw. Your truck has really come together beautifully.

 

[Chief Brody]

About as fun as crapping a pine cone.

I bought this truck in 2000 and it was truly rust-free. In fact, you could still see grease pencil markings on the underside from the factory. Most of the rust I had to fix was the result of little pockets of mud that I never cleaned out. Every time they got wet, they would just hold water. When all this is said and done, I don't think it'll be in the mud again for awhile.

Big fan of your build btw. Your truck has really come together beautifully.

thanks...mine wont see mud either...although it would see a little sand if I ever get it down to Navarre and Orange Beach

 

[Chief Brody]

why did you move up to B'Ham from the coast....I have always wanted to live down there...at the beach...

 

[rebelgregory]

Born and raised in Mobile. The beach is nice, but I've maybe been to it 6 times my whole life. I was usually IN the water salt fishing or sailing or boating on the rivers leading to the bay. The tourist-y beach stuff was never my scene. I actually still have a sailboat in the water down there.

I moved to Birmingham for a job about 6 years ago. I like it up here. The terrain is a lot nicer and the summers don't feel like a steam room, but I do miss the water. But I'm only 3.5 hours from home on any given weekend.