Project Big Block ('04 Chevy 2500HD CC 4x4)

[Daubs]

Purchased the 8.1L Big Block new from factory in 2004. Ordered it just the way I wanted it. Washed and waxed regularly, but the dreaded rocker panels are rusting. And could see rust on inside of rear wheel wells.

Purchased welder, practiced, read threads, practiced more, talked to friends, watched this video series (Project Duramax - Rust repair and painting series), and tonight I pulled the rear fender flare and started the journey.

Wheel wells first, then rocker panels. Pleasantly surprised there was not more rust hiding under there. A few "before" pictures.








Fender Flare removed...


Hit with grinder, and tapped with body hammer...Yep, RUST!



Ordering parts tomorrow. Hopefully I will be able to keep the repair inside the fender flare (i.e., easier to hide, very little body work). Crossing fingers.