So my rust problem is bigger than I thought Here are a few pics:



This is the worst of it
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Here are the cuts im thinking about. the red is across the end of the bed. The yellow is an angle cut that would kill most of the rust on both sides.

So I;m open to any suggestions or ideas. Has anyone ever gotten into something like this before I need some advice

 

If you don't cut out ALL of the rust, you will simply be wasting your time. It it like cancer, and must be completely removed.
I would rather cut into the good metal and replace some of it also, than take a chance on doing it again.
Here are some pictures of my rocker panels. Did I cut way more out than I had to?? Probably, but I know the rust is completely cut out.

Here's where it was rusted. Under both doors.



Here's how much I cut out to make SURE it was all gone. A bit of overkill.





I wanted to make sure it was a one time only job.


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nice ^ i need to do my floors body mounts and cab corners....not lookin forward to it!

 

Wow that way more professional than I was going to go. I only spent 1600 cash on this truck it has 138,000 miles pretty good deal if you ask me but I dont want to put a ton of money or time into it. I am going to cut out the rust then POR 15 everything i can get to. then ill go over it with herculiner. Its the white trash way of doing it but It wont ever rust again. I have done it this way on 3 Jeeps before and have never had any rust come back ever. The cab I'm going over very well but the bed I dont much care about I know that it will rust out again. Then I will build a flat bed for it. Any one got any ideas on the cuts for the back of the bed?

 

Trust me, there was nothing professional about it. My body work experience amounted to cutting up old stop signs and riveting them into place on my old
CJ-7.
It was definately a read what I could find, learn as I went, man on a mission type of deal.

Are you getting new panels or just patching in pieces?? I would cut above the red line you have drawn. Along the ridge in the body. It looks solid there, and will make it a lot easier to hide the seem.

Good luck. Get the rust under control and there's no reason that truck doesn't have a lot of life left in her. It will make that $1,600 investment even better.

 

Well on the back of the bed I am just going to cut and leave it as is. For now I cut along the yellow line, I can always cut to the red line later. As for the cab corner I am going to use a very fine stainless steel wire mesh to over lay the big azz hole with. Then I'm going to shoot great stuff over it from the backside through the drain plugs. Then i'll trim it down and and shape with long strand fiberglass and then do the Herculiner. I call it redneck bodywork

 

The lower cab can be replaced using patch panels available in KC at Certi Fit. The bed? You can save yourself a lot of pain by finding a rust free used bed. FWIW, you can't stop rust. I restored a 71 Mustang convertible. New floor pans, torque boxes, nos quarters, rust free doors shipped in from the south, etc. I totally disassembled the car and stripped all paint inside and out. It was good for about 5 years before it started its rust cycle all over again. When you weld you can treat the outside but the inside of your weld usually starts rusting right away.
You have yourself quite a project there but it's not impossible. Good luck.

 

all of the rusted areas you have, they make patch panels that are very cheap and if you can't weld them in you can always get panel glue

also any metal welded on thats can't be treated on the back side after being welded in should be coated with weld through primer

but if you can't afford that spray foam and fiber glass will give you a few years

 

Well almost done with this little project should have pics of it up by tomorrow. I didnt cut anymore of the back did the angle cut on it now I just need to figure out the bumper.

 

Ok well got the rust taken care of and I did the Gotts Mod while I was at it. Tell me what you think.
Lighting is pretty dim and I took the pic with my phone but you get the idea