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Rust!

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Old Feb 14, 2023 | 11:41 AM
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Default Rust!

My 2009 F0-150 Lariat has 250,000 miles on it, we put a new Ford engine in it at 180,000 after it threw a rod. The truck runs great and looks good, BUYT I now have rust in the bottom rear corner of the cab and blind the bottom of the door frame. Any good solutions to get more life out of this truck?




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Old Feb 14, 2023 | 12:30 PM
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Every truck of that era has that here. One guy on the forum cut it all out and welded in new panels. The good part is the frames do not rot, even in the severe environment here, so it is fixable!
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Old Feb 14, 2023 | 12:59 PM
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Originally Posted by NYFordTruckMan
Every truck of that era has that here. One guy on the forum cut it all out and welded in new panels. The good part is the frames do not rot, even in the severe environment here, so it is fixable!
The frames aren't nearly as bad as the previous gen F150s, but they do rot out. It's pretty common for water to get between the frame rails and the reinforcement plates welded onto the rails near the back of the front wheel wells, if the reinforcement plate is bulging there's a good change the rail is severely compromised or already has a hole in it.

The only good solution for frame or body rust once it's already there is to cut it out and replace the metal, or replace the rusted component entirely. The big problem is finding someone who will do the job properly, rust is usually way worse then it looks and the scope of a repair can grow very quickly.
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Old Feb 14, 2023 | 01:05 PM
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Originally Posted by SALEEN961
The frames aren't nearly as bad as the previous gen F150s, but they do rot out. It's pretty common for water to get between the frame rails and the reinforcement plates welded onto the rails near the back of the front wheel wells, if the reinforcement plate is bulging there's a good change the rail is severely compromised or already has a hole in it.

The only good solution for frame or body rust once it's already there is to cut it out and replace the metal, or replace the rusted component entirely. The big problem is finding someone who will do the job properly, rust is usually way worse then it looks and the scope of a repair can grow very quickly.
I looked for that when I got mine. I got can of fluid film sprayed in there . The mid sections of the frame seem to be safe. Bed supports are another problem.
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Old Feb 15, 2023 | 10:41 AM
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I can go out after a week or so of my truck sitting in one place and there will be pieces of the rocker panel laying under the side step.
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Old Feb 15, 2023 | 11:02 AM
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Originally Posted by oldsmoboat
I can go out after a week or so of my truck sitting in one place and there will be pieces of the rocker panel laying under the side step.
Have you thought about fixing it? I did see somewhere that there are plastic type of covers that can fit over that area and be painted,. I jukes you would cut our the rusted metal and hit it with a proper or something and then secure the covers over it...
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Old Feb 15, 2023 | 09:31 PM
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Originally Posted by Capt. Dan
Have you thought about fixing it? I did see somewhere that there are plastic type of covers that can fit over that area and be painted,. I jukes you would cut our the rusted metal and hit it with a proper or something and then secure the covers over it...
I have thought about, but that's not the only rusty place, just the worst. I have to build a retaining wall this spring and after I haul the materials, I'll probably just sell it.
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Old Feb 15, 2023 | 10:04 PM
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Originally Posted by oldsmoboat
I have thought about, but that's not the only rusty place, just the worst. I have to build a retaining wall this spring and after I haul the materials, I'll probably just sell it.
My next truck is going to be a 15+. No question about it.
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Old Feb 16, 2023 | 09:47 AM
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Originally Posted by NYFordTruckMan
My next truck is going to be a 15+. No question about it.
Is that when they went to all aluminum?
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Old Feb 16, 2023 | 09:55 AM
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Originally Posted by Capt. Dan
Is that when they went to all aluminum?
Yep, never saw one with rot issues. They are pushing a decade already.

Don't know about the frames, but I think Ford got that problem squared away.
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