1st paint job

[FAKKY]

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

[mongocanfly]

cut out the cancer and replace with new metal

[MP&C]

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..

[FAKKY]

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

[mongocanfly]

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

[FAKKY]

thx all

[FAKKY]

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

Frontside


Backside



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...





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 ?

[MP&C]

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..

[FAKKY]

Originally Posted by MP&C

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..

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

[MP&C]

Not the roof.... the multiple holes.
Posted via Mobile Device

[FAKKY]

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

[MP&C]

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

[FAKKY]

Originally Posted by MP&C

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

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 ....

[FAKKY]

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.

[mongocanfly]

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

[tinydb84]

Originally Posted by mongocanfly

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

I think you are referring to Ram Board.

[mongocanfly]

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

[FAKKY]

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