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Old March 23rd, 2016, 10:18 AM   #1 (Link to post)
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Had a little rust hole in the lower passenger fender. Figured I would just patch that hole and move on. Well that turned into a bit of fun.

Pull fender and find a hole in the front A-pillar, pull the rocker/pillar and find a rotted kick panel and rot in the inner rocker and cab floor support. Ended up sectioning out the rotted bits and just replacing what I had to. You have to either remove the cowl off the firewall or cit off a piece to access the A-pillar forward section.
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Old March 24th, 2016, 08:22 AM   #2 (Link to post)
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Few more pics of the replacement. Had to add a piece at the rear of the rocker, thought I had it nailed until I hung the door trying to get a perfect fit. Much bigger PITA to replace the rocker up into the pillar and get good door alignment, than it is to simply R&R a rocker skin. Once I get the welds flap disc'd it'll look a little more presentable.
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Old March 27th, 2016, 07:42 PM   #3 (Link to post)
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Good work. Sure will be a nice truck when you're done with it.
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Old March 28th, 2016, 08:10 PM   #4 (Link to post)
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That's the DQ's rocker, 14 years outside finally took a toll on it. Trimming the fenders allowed a lot of rust to form on the A-pillar area. Have to get it running by Summer when the plates are due.

Burb is mostly done except for paint, bumpers, and some small parts.

The red truck won't last much longer, the rust is so bad I probably won't be able to save it. It's rotted out in places they don't make patch panels for. Not sure I want to put that much work into fabricating from scratch. I would need a bender, english wheel, etc. It would be a hell of a project.
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Old April 10th, 2016, 12:18 PM   #5 (Link to post)
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Finished except for bondo work, got a coat of paint to keep it from flash rusting. Started on the wheel well, holy hell Batman. I shoulda bought a new one but tight budget dictates otherwise. 2 hours worth of flap disking, cut-patch-weld-grind-cut-patch-weld-grind, pain in the ass. Etch prime and seam seal just in case. There are a lot of steps to fixing that rot.

Not a big fan of the rust.
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Old April 10th, 2016, 05:07 PM   #6 (Link to post)
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You do nice work, James! When you gonna come down and help me fix the holes in Elway?
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Old April 11th, 2016, 11:39 AM   #7 (Link to post)
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Quote:
Originally Posted by 3 on the tree View Post
You do nice work, James! When you gonna come down and help me fix the holes in Elway?
Thanks Mike, soon as I fix the hole in my pocket.

8 more months, 8 more months, 8 more months. Hey I was thinking we could do some stick ups, Butch and Sundance style. There are a lot of wealthy dumb asses in Washington, think they might donate to our cause?

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Old April 11th, 2016, 10:02 PM   #8 (Link to post)
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Quote:
Originally Posted by Cricket View Post
Thanks Mike, soon as I fix the hole in my pocket.

8 more months, 8 more months, 8 more months. Hey I was thinking we could do some stick ups, Butch and Sundance style. There are a lot of wealthy dumb asses in Washington, think they might donate to our cause?

We are neither right wing evangelicals, or left wing bleeding hearts, so no donations for us.
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Old April 12th, 2016, 11:16 AM   #9 (Link to post)
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Got the fender skirt in, not too bad a fit considering how many sections were welded. I drilled the lowest hole in the rear of the wheel well 1 1/2 bolt widths off. Decided to slot that area with a cut-off wheel and weld a big washer in the correct spot. Engine looks like a grease ball in comparison, will clean it up later on.

It'll do.
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Old April 12th, 2016, 03:05 PM   #10 (Link to post)
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Looking through the glovebox frame for reference.

If you pull the vent assembly in the kick panel you can get a brush up into the cowling. I put a coat of implement enamel anywhere I could reach, did the same inside the A-pillar but your limited by the small size. My hand was too big to get very far up it - the cowl hole is a lot bigger and you can run your arm pretty much all the way up into the cowl drain area.

Doing anything I can to keep the rust from creeping.
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