F250 rust repairs

[dieselcrawler]

Spent 4-5 hours on my back under the truck today... tryed to get a nap but the creeper was uncomfortable and the paint fumes kept me awake. I brushed some Rubberized Rust Incapsulator on the spots where welding burned off the paint, and re-coated any seam I could get the brush on... inside the front cab mount cavity, the bottom of the floor pan/trans tunnel seam, inside floor supports where the meet the rocker pannels. My shoulder did not like so meny hours of holding my arm over my head.











Got the top side of the floor pan painted... quick slap-a-brush job but it gets the primer covered good. Can't see it once the interior is back in.

 

[Nightforce]

Hey Greg,

I absolutely love this thread!

Rebuilding a car or truck with this extent of decay can be a real challenge....even if you know what you're doing! Back in the day I did several restorations and enjoyed seeing the step by step progress and most of all the finished result!

You're doing fabulous work and as you pointed out, the panels and new sections must fit exactly right otherwise a door won't shut or mating panel will be misaligned. Superb work and thank you for taking all the photos and posting them. :thumbsup:

I'm bookmarking this for quick retrieval...

PS...Make sure you rust proof the crap out of the new sections!

 

[dieselcrawler]

Been busy sawin lumber at work so no progress on the truck... untill yesterday. Did a little sanding, and primer... today I wet sanded the primer and everything else getting paint with 600 grit, dried it all off, masked it where needed, and sprayed about 3 1/2 cans of Rust Oleum Gloss White on the rockers and cab corners, up to the roof line. You can see the seams where the cab corners were welded in, but concidering how little effort I put into covering them with filler properly, I'm happy with how it turned out. Will add pictures later... not downloaded yet.

 

[dieselcrawler]

Masked off and ready to spray... time to rattle a can!



All painted up...












Premature gray? Couldn't be overspray...

 

[terryknight]

looks great from here

 

[dieselcrawler]

Nightforce: thanks for the compliments... glad you're enjoying following my work.

Rust proofing everything is at the top of the priority list. There are a few captive areas that have perplexed me as to how to cover the heat damage from welding on the inside... between the inner and outter cab corners for one, and to a lesser extent, inside the rocker panels. Otherwise, I'm painting/undercoating the **** outta everything I can. I still need to paint the bottom of the floor pan too.

 

[dieselcrawler]

Terry: looks great from my house too... glad the truck is at work, 3 miles away!

But really... its a work truck so rust free with a few minor blemishes done sooner will make the boss man happy as a pig in slop. We're going for 30/30 bodywork/paint job... from 30 feet at 30 miles per hour, it will look awesome! If it were my own personal project, I would have prefered to put some extra time/effort into a few cosmetic details that I was told to skip. I would have liked to paint the roof and hood too... no go.

 

[NS Gearhead]

There are a few captive areas that have perplexed me as to how to cover the heat damage from welding on the inside... between the inner and outter cab corners for one, and to a lesser extent, inside the rocker panels.

That's where little access ports for undercoating are key. I love Rustcheck myself, but Fluid Film or something else works.

Not sure if it's common... where I have my cars done, they drill little holes (1/4" or so) so they can shove the spray wand in there and reach those areas. Then place a little cap to cover the hole. Tried finding a pic or two in Google search, but nothing. Leading me to think it's not that common. LOL

 

[Scooby074]

That's where little access ports for undercoating are key. I love Rustcheck myself, but Fluid Film or something else works.

Not sure if it's common... where I have my cars done, they drill little holes (1/4" or so) so they can shove the spray wand in there and reach those areas. Then place a little cap to cover the hole. Tried finding a pic or two in Google search, but nothing. Leading me to think it's not that common. LOL

It used to be much more common back in the day. Now people stress out when someone takes a Unibit to their new car. Honestly though its the best way to ensure that oil reaches the hard to get spots like the A pillars and frame around the windshield.

My Tacoma (96) is drilled and Krowned. Not a spot of rust on it, knock on wood.

 

[dieselcrawler]

No pictures today... put the back glass in, put all the floor hole plugs/grommets in, and then spent most of the afternoon painting the underside of the floor pan and back side of the rocker panels. Should be ready for carpet/interior tomorrow.

I will have to check into the undercoating wands... I think I can cover what I need without drilling any holes.

 

[dieselcrawler]

Done... kinda. Interior complete. Old rusty doors and fenders back on. Bed next... then a road trip for rust free southern doors and fenders, and frame section from cab back.

 

[Paul Thornton]

WOW! What a great job!

L2800 w/FEL - 72" Land Pride rake

 

[dieselcrawler]

No truck work this morning... sawed a few logs, then put a tie rod end on the boss' wife's caravan. After lunch I got some time to straighten out the rats nest of wires going to the tail lights. I don't have 'before' pictures but heres what was done...

I soldered extentions on the wires going to the trailer 7 pin plug and mounted it in the rear bumper, and eliminated a bunch of needless splices and jumpers on the bed harness, soldering and heat shrinking directly to the lights. Once the bed is on, its a matter of snapping two connectors and its good to go.

 

[dieselcrawler]

Got the bed on today. Had to modify the front bed mounts but no pictures of a rather un-notable modification.

There are some flatbeds that look sharp. This is not one of them...

 

[terryknight]

can't you build your boss a nicer flatbed?? haha

 

[dieselcrawler]

Terry: sure I have the ability... just not the orders to do so. I wanted to straight pipe it too but that idea didnt make the to-do list eather.

 

[aczlan]

Terry: sure I have the ability... just not the orders to do so. I wanted to straight pipe it too but that idea didnt make the to-do list eather.

That exhaust system is looking pretty rusty isnt it ::cough cough:: be a shame if you were to find some nasty holes in it ::cough cough::

Aaron Z

 

[forgeblast]

amazing (re-)build!
Just wondering about a rust preventative, I saw a product called "fluid film" have you ever used it?

 

[chim]

..................... There are a few captive areas that have perplexed me as to how to cover the heat damage from welding on the inside... between the inner and outter cab corners for one, and to a lesser extent, inside the rocker panels. ..........................

Nice work! Many years ago I redid a K5 Blazer. The doors (and I think the rocker panels) had drain slits that I stuffed rags into. There were some access holes already there by using openings for the tail lights and vents, but I drilled a few as well. I then pumped tar into the cavities and allowed it to soak before pulling the plugs and draining the tar. I figure the cavities had close to 6" of good coating inside and that's where the worst of the rust was to start with. A piece of copper pipe on a hose allowed me to reach in the tail light holes and thoroughly coat the area above the rear wheels where the "rusty eyebrows" were cut out and patched too.

 

[dieselcrawler]

Chim: that's a good idea... hot tar (no feathers please) piped in to places. I'll have to see if it might work in some of the areas. Some it won't... others maybe.

When I was a kid my dad had an undercoating gun that used air to propel undercoating from a gallon jug. I haven't seen it in 15-20 years, and my local parts store guy said they don't sell under coating in gallons now... I dunno.

For now... boss man was grinnin like kid who just got his licence when he drove the truck out of the shop lot back to "his" parking spot... now if he'll just go get new doors!