ILoveMyPatty Posted April 4, 2006 Share Posted April 4, 2006 Okay so I removed all four fender flares the other day, and revealed some "surface rust"... Surface rust... pchhh.. yeah right. After grinding away at the rust, it got deeper and deeper, wider and wider.. Now I'm left with multiple holes around my fenders and rockerpanels. I am scrooged! Drivers side rear fenderwell/rockerpanel. Drivers side front rockerpanel area... I know I know.. It's absolutely hideous... It spread like a wildfire while my truck was dirty... Passenger side behind wheel well. Passenger side rear wheel well. Passenger side front fenderwell. As she sits right now. I have no idea how I'm going to fix these massive holes. I really need some tips, they would be greatly appreciated. Help pleeease! Thanks! Link to comment Share on other sites More sharing options...
94extreme Posted April 4, 2006 Share Posted April 4, 2006 probably will need to weld on some new sheet metal. Link to comment Share on other sites More sharing options...
89_trailboss Posted April 4, 2006 Share Posted April 4, 2006 HAHA, That is NOTHING!!! I had to cut my whole passanger rocker out and the front passanger fender is lookin for a new home in the dump. best bet it so cut around the rust and weld new stuff on. Link to comment Share on other sites More sharing options...
ILoveMyPatty Posted April 4, 2006 Author Share Posted April 4, 2006 I don't know how to weld though Link to comment Share on other sites More sharing options...
OR99.5Speed Posted April 4, 2006 Share Posted April 4, 2006 Hmmm...do you know anyone who can weld? I know POR-15 stops it for the time being...I would search the Internet for tips on how to do that stuff as a temporary stop while you find a welder. Link to comment Share on other sites More sharing options...
ILoveMyPatty Posted April 4, 2006 Author Share Posted April 4, 2006 Gah I'm angry...I was just getting money to do the JGC/UCA lift and a body lift Link to comment Share on other sites More sharing options...
GrimGreg Posted April 4, 2006 Share Posted April 4, 2006 For that front passenger fender I would just get a new one, everything else just patch up. Link to comment Share on other sites More sharing options...
mws Posted April 4, 2006 Share Posted April 4, 2006 If you want the repair to be good looking and hard to notice, you really have no choice but to have a metal craftsman form and weld in new sheet metal. If you just want to plug the holes and stop the cancer and really DON'T care what it looks like, you can patch it up yourself with minimal skills or expense. - grind off ALL evidence of rust, - coat the inside of the panel with POR-15 to stop the rust from continuing to spread on the inside. - shoot some 2 part expanding foam into the cavity (foam that is compatible with resin!) - shape the surface of the foam so it looks kinda like what the metal used to look like. - Lay a couple layers of fiberglass over the top. Depending how well you did, it may (or may not) look like h#!!, but it will stop the rust and let you drive it for a few more years. Link to comment Share on other sites More sharing options...
thatguy03 Posted April 5, 2006 Share Posted April 5, 2006 what is this POR-15 and where do you get it?? Link to comment Share on other sites More sharing options...
mws Posted April 6, 2006 Share Posted April 6, 2006 http://www.por15.com/ Link to comment Share on other sites More sharing options...
ILoveMyPatty Posted April 7, 2006 Author Share Posted April 7, 2006 mws, that sounds like a dern good idea if I might say so myself... I was actually thinking about expanding foam, but didn't know if there was some that would be HARD. Link to comment Share on other sites More sharing options...
GrimGreg Posted April 7, 2006 Share Posted April 7, 2006 I was actually thinking about expanding foam, but didn't know if there was some that would be HARD. That''s where the fiberglass comes in Link to comment Share on other sites More sharing options...
ticker Posted April 7, 2006 Share Posted April 7, 2006 put the flares back on! Link to comment Share on other sites More sharing options...
mws Posted April 7, 2006 Share Posted April 7, 2006 Talk to the folks at a fiberglass supply place. There are special foams that are resistant to the resins. Many foams will dissolve so you have to use the right stuff. We used to use florists foam for building plugs to make molds - but it comes in solid blocks and not injectable. Here's a good source for materials and knowledge - been around for decades. http://www.aircraftspruce.com/menus/cm/foam.html Link to comment Share on other sites More sharing options...
nige Posted April 7, 2006 Share Posted April 7, 2006 i heard expanding foam is a no-no because it retains moisture Link to comment Share on other sites More sharing options...
GrimGreg Posted April 8, 2006 Share Posted April 8, 2006 Drivers side rear fenderwell/rockerpanel. Heh, started poking at the rust on my 93 in that area (fixed once 3 years ago), it looks a little worse than that, guess I didn't kill all the cancer so it came back. Guess I found my next project on that truck Link to comment Share on other sites More sharing options...
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