Need advice on body work/ rust removal

[popsmckracken]

I'm putting a lot of time and money into this build for my son. I can no longer ignore the elephant in the room. I don't know much about where to begin here or what is available in terms of panels, replacements, materials etc. I'm a greenhorn welder so I'm not sure this is a job I can handle but I always prefer to do things myself where I can. If someone could take a look at this mess and point me in the right direction it would be greatly appreciated. Thanks

 

[Unner]

The right direction is South to buy a rust free truck... Those pictures made me cringe.

Sorry, but I don't know that it is economical to replace those parts of the truck or not. That's a lot of welding and in a difficult place too with the rocker panels being totally gone. Especially if you're new to welding. How does the frame look if the body is that bad?

 

[MN4runnerman]

For the wheel lip fender area clean up the rust and treat those spots. Then use some Bondo to fill the holes, sand and then paint to match. Then cover them up with fender flares; either some oem ones from someone in the classifieds or some bushwhacker ones. For the rockers there's a way to do it without welding. You can cut the bad stuff out and, using a rivet gun bend new sheet metal in and and use some seam sealer.

This is just a general description. I can get into more detail if you have more questions.

 

[Scramble]

I'd buy a doner truck with a blown engine. Cut it up & replace panels. Or transfer motor to the doner if body & frame are better.

 

[amalik]

I'm with [MENTION=116387]Unner[/MENTION] on this one.

Forget trying to worry about the body for now. What does the *frame* look like?

You are wasting all your time and money if you are investing and fixing up your sons truck if it has a rusted frame that makes it *DANGEROUS* to drive in the event of a collision.

Remember, safety first.

 

[popsmckracken]

The right direction is South to buy a rust free truck... Those pictures made me cringe.

Sorry, but I don't know that it is economical to replace those parts of the truck or not. That's a lot of welding and in a difficult place too with the rocker panels being totally gone. Especially if you're new to welding. How does the frame look if the body is that bad?

That is the only rust on the body. The frame has some rust but nothing critical. This was the exact spot where a shop did a repair from an accident 7 years ago.

 

[popsmckracken]

For the wheel lip fender area clean up the rust and treat those spots. Then use some Bondo to fill the holes, sand and then paint to match. Then cover them up with fender flares; either some oem ones from someone in the classifieds or some bushwhacker ones. For the rockers there's a way to do it without welding. You can cut the bad stuff out and, using a rivet gun bend new sheet metal in and and use some seam sealer.

This is just a general description. I can get into more detail if you have more questions.

thanks for the practical advise. Like I said This the only rust on the truck. Is it possible to get new rockers? If I can't weld it I'll get my buddy to do it.

 

[Skibber]

This was the exact spot where a shop did a repair from an accident 7 years ago.

You can see the bondo from the previous repair. Rust may just be working it's way out from the repaired areas. Maybe not done properly if it was only 7yrs ago. My midwest truck has almost zero body rust, but I do have passenger side frame rust next to the muffler which I am addressing soon.

 

[reelamin]

That is the only rust on the body. The frame has some rust but nothing critical. This was the exact spot where a shop did a repair from an accident 7 years ago.

That is a ton of work...requires cutting it out and patching in new panel patches....then body work to make it look clean...that have to be cut to fit....not aware of any "aftermarket patch panels" like classic vehicles.

I don't know how some of you dont have a literal revolution against your road departments and states. They are costing their citizens 100's of millions in travel costs. They started that salt crap in WA just a couple years ago....and it is showing noticeably...and they are dumping more and more salt every year. F'n idiots!!!!

 

[popsmckracken]

That is a ton of work...requires cutting it out and patching in new panel patches....then body work to make it look clean...that have to be cut to fit....not aware of any "aftermarket patch panels" like classic vehicles.

I don't know how some of you dont have a literal revolution against your road departments and states. They are costing their citizens 100's of millions in travel costs. They started that salt crap in WA just a couple years ago....and it is showing noticeably...and they are dumping more and more salt every year. F'n idiots!!!!

Well, this is more a case of a repair that was not done properly. I actually went back to the shop and of course the guy didnt remember me. I told him it was where I had a repair done , keeping quiet about where and he went into a diatribe about how low end shops do this all the time then.... I dropped the bomb on him. He turned all shades of red and blamed it on bad help. haha

 

[Scramble]

Well, this is more a case of a repair that was not done properly. I actually went back to the shop and of course the guy didnt remember me. I told him it was where I had a repair done , keeping quiet about where and he went into a diatribe about how low end shops do this all the time then.... I dropped the bomb on him. He turned all shades of red and blamed it on bad help. haha

That's awesome! :thumb3:

 

[popsmckracken]

That's awesome! :thumb3:

Yeah and this is one of those shops with an unpronounceable German name where all the guys wear jump suits and look down their noses at your car if It hasn't qualified on the autobon.

 

[MN4runnerman]

thanks for the practical advise. Like I said This the only rust on the truck. Is it possible to get new rockers? If I can't weld it I'll get my buddy to do it.

Supposedly this place has rockers. Toyota 4 Runner Body Panels I read about some fitment issues but if you're cutting and welding I don't think it matters much.

After looking over their site they don't list rockers for our years but I bet you could get 2nd gen ones to work. They do have the little dog leg where most of your rust is.

 

[Timmy1909]

I just ordered Rockers from robin at wolf steel restorations today. 1996-2001Toyota 4 Runner Body Panels

The rockers he sells will need to be modified to fit as they do not include the provision for the pillar. here is a pic of them:

They were $75 per side and $30 for shipping to the US. if you have any questions give Robin a call, He is very cool to talk to and knows what he is talking about.

I will be replacing rockers in a 98 I just bought really cheap. I need a new project. This 4runner also has some frame rot witch is being addressed by a fabrication shop. I will try and do a write up on the rocker replacement... I just need to get 15 posts so I start a thread.

 

[IBallEngineer]

For the wheel lip fender area clean up the rust and treat those spots. Then use some Bondo to fill the holes, sand and then paint to match. Then cover them up with fender flares; either some oem ones from someone in the classifieds or some bushwhacker ones. For the rockers there's a way to do it without welding. You can cut the bad stuff out and, using a rivet gun bend new sheet metal in and and use some seam sealer.

This is just a general description. I can get into more detail if you have more questions.

Sorry, that is just really BAD advice. Plastic filler is not intended to fill holes, nor is it a good way cover rust. Plastic filler has no barrier to moisture, it requires, primer and paint. If you put in a hole, the moisture from the other side will cause it to bubble and blister. That's why you can't patch a radiator with BONDO.

:fish:

 

[MN4runnerman]

Sorry, that is just really BAD advice. Plastic filler is not intended to fill holes, nor is it a good way cover rust. Plastic filler has no barrier to moisture, it requires, primer and paint. If you put in a hole, the moisture from the other side will cause it to bubble and blister. That's why you can't patch a radiator with BONDO.

:fish:

I never said it was good advice. It's more of a it's the cheapest option out there(I didn't even get into filling gaps with spray foam yet if you want really bad advice). Obviously cutting out the crap and welding in new sheet metal is the best option. I could've clarified it better though.

 

[popsmckracken]

I just ordered Rockers from robin at wolf steel restorations today. 1996-2001Toyota 4 Runner Body Panels

The rockers he sells will need to be modified to fit as they do not include the provision for the pillar. here is a pic of them:

They were $75 per side and $30 for shipping to the US. if you have any questions give Robin a call, He is very cool to talk to and knows what he is talking about.

I will be replacing rockers in a 98 I just bought really cheap. I need a new project. This 4runner also has some frame rot witch is being addressed by a fabrication shop. I will try and do a write up on the rocker replacement... I just need to get 15 posts so I start a thread.

You da man. Much thanks When you say the "pillar" what exactly are you referring to?

 

[popsmckracken]

Here's a question, after all this is said and done why wouldn't I just buy a rear quarter panel that's already got matching paint? I know I'd still have to do the rocker but it seems to me after welding, grinding, plastic, etc it would make more sense??

 

[MN4runnerman]

Here's a question, after all this is said and done why wouldn't I just buy a rear quarter panel that's already got matching paint? I know I'd still have to do the rocker but it seems to me after welding, grinding, plastic, etc it would make more sense??

If you buy a paint matching quarter panel you still have to cut to fit and you'd sand down the areas to weld the new panel to the body. You're still gonna end up painting something. Rockers not so much you can get away with a paint matching rattle can down there but on a quarter panel it wouldn't look good. At my work we use Cromax paint and it comes ready to spray. It blends itself and if done right it's always within 1% of a match. It's not that hard compared to other paints.

 

[SpidermanGeek]

I just ordered Rockers from robin at wolf steel restorations today. 1996-2001Toyota 4 Runner Body Panels

The rockers he sells will need to be modified to fit as they do not include the provision for the pillar. here is a pic of them:

They were $75 per side and $30 for shipping to the US. if you have any questions give Robin a call, He is very cool to talk to and knows what he is talking about.

I will be replacing rockers in a 98 I just bought really cheap. I need a new project. This 4runner also has some frame rot witch is being addressed by a fabrication shop. I will try and do a write up on the rocker replacement... I just need to get 15 posts so I start a thread.

Awesome. Bookmarked the link. They're only a 3 hour drive from me.

My driver's side dogleg and both rockers are toast.