Rust sucks.

[surfnuke9]

Dont think this is gonna buff out....

[Hobcobble]

Yowser...... That is probably one of the
more common places our trucks rust out
from..... and one of the toughest to
repair. I know
how you feel though.... I have some
really bad issues in the same area on
my '61 D200.
John

[surfnuke9]

Yeah, figured it was common and NOT easy to fix.....the other side is starting too.

[wally426ci]

That sucks.

On a good note, its all flat metal, so if you can weld it won't be too hard.

[sneezingduck]

hejsan
dont worry... its a pretty easy place to start pratice your welding skills

1. remove the fender.
2. get some metal , make a 90" bend and make the curve over a tube....done
3.start welding ( no hurry )

[soopernaut]

Just cut the pieces out of some junk doors. It takes all the guesswork out of making curves, bends, etc.

[surfnuke9]

I was thinking of exactly that while looking at it the other day.

[Boons]

Heres how I did mine.
PO payed someone to do this......I would want my money back.

Cut it out

The door

Peice Fitted gotta love gap Take your time when measuring and fitting other wise you end up with some nasty gap to fill.

Looks good.

Tacked in

Welded.

Now What I thought was good metal....was not, kept burning through so I gotta cut it out and redo it.

Now to blend it, this is the kinda disc I used, its a Walter Flex-cut sanding disc.You can also use a flapper disc.When grinding never stay in one spot for too long, when you see the metal changing color thats bad lol.Grind till the weld disapears into the material.


Done blending and as you can see a problem as come up...My ill patience gets the best of me again .Were I thought was good metal once again was thin.Ill have to go back and fix it.

when your welding do it in a series of tacks giving about 10 mins before each string.Put yours Welds like you were tightening lugs on a tire.

I hope this helps.Bodywork is about 25% skill and 75% patience......I lack alot on patience and could have made this perfect.I didn't give enough time for the metal to cool and I warped it a little.Anything is better than what it was.Have any question feel free to PM me.
Ill also through a picture up of when its all done.

[surfnuke9]

looks OK to me Boons. Thanks for the pics.