Hi Everyone, I’m new to the Forum and was wondering if anyone had any ideas about some rust fixes. I have a 2010 F-150 Supercrew. Made in the Dearborn Plant was was driven around Saskatchewan, Minnesota, Manitoba, Wisconsin, etc. as a surveying vehicle before heading here. It seemed to have some surface rust and I could see a spot where someone attempted to do a foam fix and didn’t do a very good job but I later found a couple small spots where the rust has rotted through on the cab corners. I talked to a couple auto body shops about new panels and it’s safe to say that getting new panels welded will not be an option because of the price. I’ve heard of foam, JB weld, fiberglass, cab corner and rocker panel covers, etc. I was wondering if anyone had an good ideas. It’s also important to point out that I live in Oregon and rust really isn’t an issue here. For the most part once you get it taken care of it doesn’t come back very aggressively if at all.

 

That's very minor, and the foam looks factory. Any decent auto paint/body man/shop should be able to fix all of that under a grand. Most of your pics show areas that only need scuffing & painting, or just washing & undercoating. I only noticed a couple that need the seam sealer removed/replaced or actual body filler.

 

Your "rot thru" inside the door "hole" would disappoint me quite a bit. clean it up , rust converter the snot out of it inside and out, then fill the hole bondo,I would even consider embedding a layer of fiberglass cloth. Sand & Paint, Then add to your oil change routine to pull the body plugs and squirt rust inhibitor in there, I use WD 40.(aka water displacement formula 40), put it inside the doors * tailgate too to keep the "water displaced" from those bottom seams.

I had my '92 XLT for 17+ years, the rockers never looked bad..NO body rot / rust anywhere on the truck!!.

When my 09 XL rockers started to rust
1) I was very disappointed, every oil change I squirt WD40 in all the body openings (pull the plugs) to avert rusted doors, tailgate, cab corners and inside the rockers etc.
2) I took extra action=>.

My neighbor has an 1997 F250 XL he bought new, immediately after buying it he coated the rockers inside and out with bed liner paint, they still look great to this day.

I coated mine with rust converter, then coated the rockers and bottom 6" of the doors etc with bed liner paint..(see picture) I like the way it turned out.. I hope I can make my 13 old baby last another 7 + years.

2 Perspectives:
-What ever Ford did since 10992 didn't work as well, @ 17 Years my '92 had NO RUST, and I did nothing other than wash it and squirt WD 40 in all teh "body holes".
-I wonder, has the aluminum they now use hold up better? If not maybe they should follow GM's lead in the Avalanche, Almost EVERY Chevy on the road the tailgate (here in Michigan) rots away around 10 years or so.. I have an '04 Avalanche the tailgate doesn't rot.. It is composite.. maybe all tailgates and rocker panels should be composite..

lesson learned, when I likely replace my '09 with a 2030, if the rockers are metal, I'm coating them inside and out.