1st paint job
 

Getting ready to paint here 1st time in next few weeks.
Cleaned off some suspect areas to see what Im dealing with.

Would you guys cut and weld/replace this - or use a bondo metal filler


https://i.imgur.com/Z1yTROel.jpg

Re: 1st paint job
 

cut out the cancer and replace with new metal

Re: 1st paint job
 

Paint is going to be the most expensive part of it. If the rust isn't fixed correctly, your paint will be short lived. Bondo will not keep the rust from returning. Get rid of the rust, weld in some new metal..

Re: 1st paint job
 

thanks guys - figured as much ...

2 qq

1) Whats the typical gauge sheetmetal to use for these trucks

2) When you tack weld .... do you literally weld it all up so no pin holes ..... or just mostly and the epoxy will seal off any pinholes - like how serious etc

Re: 1st paint job
 

match the metal thickness with whats there..you can pick up a metal gauge at cardboard frieght for just a few dollars..
it really needs welded solid..taking your time and doing spot welds..
grind your spot welds ( but only the spot welds) as you go and hammer and dolly the welds to combat the shrinkage
MP&C and John the astronaut are masters at doing this and making it look as if it were never touched..
be sure you use epoxy primer over your bare metal

Re: 1st paint job
 

thx all

Re: 1st paint job
 

So dug some more to see this area and other areas .....

Frontside
https://i.imgur.com/TPtbJKxl.jpg

Backside
https://i.imgur.com/VCpU0rFl.jpg


Q1) Should I patch it from the rear after cleaning ..... and using a weldable primer on the metal. Then it would be sealed and just a small mount of filler required to smooth out .... or tackle it from front - just worried about metal thickness and curves...

https://i.imgur.com/KQsLKWel.jpg

https://i.imgur.com/jIi26QLl.jpg

That could be a tough weld going straight into the drip edge as well ......
thoughts on patching over the top with primered metal ....... and thin metal pagtch and smoothing out with filler.

Best approach ?

Re: 1st paint job
 

Can you take a picture of the quarter panel that shows the whole panel? need to see the whole thing to make recommendation for weld seam location..

Re: 1st paint job
 

Sorry which one ?

The weld seam on the drop edge is the roof ....... (single big hole) - rear drivers side.

The other one with multiple holes of rust where I also cut into rear is the rear drivers side panel by bumper.


-- both have similar issues on both sides of truck

Re: 1st paint job
 

Not the roof.... the multiple holes.
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Re: 1st paint job
 

https://i.imgur.com/JGbc4I9l.jpg

https://i.imgur.com/z1LXAbwl.jpg

https://i.imgur.com/WOVNjIGl.jpg

There was probably over 1/8th inch of bondo near the rear tire well flare ..... going into the patch they had tried before ....

Re: 1st paint job
 

Do they make patch panels for that quarter panel or do you plan on making a patch?

Re: 1st paint job
 

PLan to make my own ...... have a bunch of sheetmetal offcuts in various gauges on its way to do some practice TIG .... been a while ....

Re: 1st paint job
 

Still waiting on my sheet metal to come via usps ......

Founds more damage.
What do you guys recommend for getting the tightest fit for new cuts. Going to try and TIG most of this.

Re: 1st paint job
 

I use heavy paper..we call it chipboard at work, lowes has a similar paper in a roll..but I cant think of the name...
It's like a real heavy cardboard type paper,,,it works good for making template patterns

Re: 1st paint job
 

I think you are referring to Ram Board.

Re: 1st paint job
 

That's it,,,,ramboard...thanks...

Re: 1st paint job
 

Thanks guys ..... work has begun.
Practiced tig welding on 22GA to get it dialled in .....
Going to go pickup some 20GA today ..... hour drive away for nearest metal supplier