OK, my 91 chevy pickup ext cab, with 185000 miles, had a HUGE rot spot in the side of it, under the extended part of the cab. So I decided that I would take it on. I didn't wanna spend the 100 bucks for the prefabbed panels so I decided to spend the 20 bucks for mild steel and go it that way. This is how it ended up. I know its far from perfect, but after 10 hours I just wanted to call it quits. Its a 91 that I drive daily so it looking magnificent really isn't a priority, getting it to stop rusting was! I am really looking for suggestions for the other side which I have to do as well.
My photo bucket page
The start of a very long weekend
Another shot closer to the door
angled so you can see that it goes around the back of the cab as well.
I cut out the rot to get to good metal, thank god there was some!
an up shot to see the extent of the damage
as you can see, it was quite a big hole!
Cut around the back of the cab as well, the hole was about 2'3"
you can see surface rust on the inside, I took care of that as well
grinded out the paint around the area of interest
I forgot to take more pics so this is one of after I cut, rolled and welded the metal around the hole. This is me grinding the tack welds smooth.
After I grinded and the hole is filled
I first used bondo glass (short stranded fiberglass in bondo) sanded and then used plain bondo over that to smooth it out.
As you can see all the shadows from the 500 watt hologen work light shinning down onto it after I painted.
This is with just the flash from my camera, as you can see, it looks a lot better but its still not smooth at all. After 10 hours of work I was ready to just be done!
I repaired some random surface rust spots as well and sanded and painted the entire lower half of the truck
I also tried to bang out a huge dent in the bed with a hammer, I know I know, I shouldn't have but I figured I would just glass it later, for now it looks better than it did and its painted.
So what do you guys think? Any suggestions? Like I said, I have never done any of this and just pulled everything out of my ass on what to do. I did notice that where I sanded bare metal and just primed and painted you can see scratch marks under the paint, not too concerned tho. should I have clear coated it? thanks
Scott
When I boost, you boost, we boost
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You have been banned from NEJBODY.
You've displayed wayyy too many acts of pushing people to their limits.
It's never cool to tear people down for what they want to do.
NEJBODY is a team. We're not the same as JBO where everyone bashes on eachother.
I'm surprised you show up to our meets after half of the things you say on here.
Good job for being your first time. I bet you have a greater respect for body shops now. Look at it this way you have to start somewhere.
"Remember do what you like because you have to drive it."--Me
that looks pretty good to me. well done. use some of that rubbing compound from 3m maybe it will get the little scratches out?
why didnt you remove the body side molding?? would have made for a more easier repair, did you use a weld through primer before welding?? after grinding you should have feathered out with 80, shaping bondo with 36 right before it gets hard is the best thing to do remember feather edging is the key to remove the scratches you see
now you should repaint the car and sand it back down using maybe 120 then 180 then re parime
but my eyes see that it is still very rough and really doesnt look right
rust repair is not easy, neither is bondo work
i gave you suggestions but i can not teach you online just impossiable
can i haz bondo
big daddy wrote:why didnt you remove the body side molding?? would have made for a more easier repair, did you use a weld through primer before welding?? after grinding you should have feathered out with 80, shaping bondo with 36 right before it gets hard is the best thing to do remember feather edging is the key to remove the scratches you see
now you should repaint the car and sand it back down using maybe 120 then 180 then re parime
but my eyes see that it is still very rough and really doesnt look right
rust repair is not easy, neither is bondo work
i gave you suggestions but i can not teach you online just impossiable
Haha, talk about busting his balls.
He ALSO forgot to bring me a beer, but im not complaining.
It looks good for your first big removal, try using a block next time, you will get a straighter line.
But again, nice first work
I'm back from the dead.
Currently Driving: RSX Type-S.
My Cavalier Burnt up :-(
