Opinions on repairing my rust

[skaneever]

As you can see the northern NY salt has been feasting on my truck for years. I'm not sure how well it was taken care of, as I've only had it since early December, but I'm guessing not much was done along the lines of prevention. My question is, should I try to patch this mess up, or just try to find some used rust-free replacements? The box is structurally sound, very rigid, the bed has no holes in it that I can see from underneath. The inner wheel wells are in good shape, but the outers are just as bad as the arches. Any opinions are welcomed, I want to fix her up, she runs great and only has 126k on the clock so I won't be looking for a new truck. Thanks guys.

http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_143748.jpg
http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_144025.jpg
http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_143948.jpg
http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_143917.jpg
http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_144004.jpg
http://i1256.photobucket.com/albums/ii486/skaneever/2012-02-10_143859.jpg

[1998454]

Looks like it's time for bedsides, fenders and cab corners. Why does the bed and cab not line up? I just sold a bed, same color even.

[skaneever]

The rubber in the cab mount on that side is compressed much more than the other side. It sucks, I hate that it doesn't line up. The mounts are good tho. Whoever put the body lift in just didn't address it, or caused it, my guess is the latter.

[1998454]

Easy fix with a new bushing then. I've gotta put new cab corners and rockers on mine as soon as it warms up.

[skaneever]

I need to wait for the weather to cooperate as well. I'm thinking the bushing was weak and when they tightened it up after putting the block in that it just crushed up. If it broke after the fact it would just fall out and/or have some movement, no? It appears and feels real tight and solid.

[skaneever]

They didn't change the rear bumper brackets either. Got the "gap".

[1998454]

Sweet!! Love that look! lol.
They didn't change the rear bumper brackets either. Got the "gap".

[skaneever]

Right! Lol, It's about as awesome as the gap between the bed and the frame!

[1998454]

what's even better is when the bumper is raised and the hitch is left hanging.
Right! Lol, It's about as awesome as the gap between the bed and the frame!

[skaneever]

How would you get around that? I was thinking about getting brackets to fix it, but I need to keep my hitch to tow my boat. I need a new hitch as well cuz.... you guessed it, ROTTEN! Gotta love straight salt on the road for 5 months out of the year! Maybe just do a custom bumper thats taller, I don't know, list is getting long! Another thought on the fenders, I could just cut em out and do pocket flares and stuff some big rubber in there.

[1998454]

There's another thread here somewhere on the hitch. I think someone mentioned an escalade hitch fitting our trucks with a body lift. It would definately be cheaper to find some form of a cutout flare.

[1998454]

http://www.fullsizechevy.com/forum/general-discussion/offroad/490240-hitch-body-lift-question.html

[skaneever]

Thanks for the link. After seeing whiplash's truck with the brackets it doesn't look bad with the lower hitch, would make it easier to spray the salt and sand off in the winter too.

[old chevy man]

That'll be a fun project to fix up! My dad and me are going to be doing the same to his 90 Z71 here I think when it warms up. New bed, doors, fenders, cab, more or less a whole new body on his frame. His is a little worse than yours though I think, Lol, you will have to keep us posted.

[cancritter]

frame off..blast frame...replace cab corners and rocker panels under doors..will gareentee thier toast by pics..round up new box and front fenders..chances bolts holdin inner to outer will be toast..honestly would replace both as l know what yer gona run into..in all honesty best to replace than try to repair..front fenders and inners are cheap...boxs are cheap and plentyfull...LMC for cab corners and door rockers..local pick a for assorted small parts and SEM paint for rest

[skaneever]

That'll be a fun project to fix up! My dad and me are going to be doing the same to his 90 Z71 here I think when it warms up. New bed, doors, fenders, cab, more or less a whole new body on his frame. His is a little worse than yours though I think, Lol, you will have to keep us posted.

Definitely will post progress when I start.

[skaneever]

frame off..blast frame...replace cab corners and rocker panels under doors..will gareentee thier toast by pics..round up new box and front fenders..chances bolts holdin inner to outer will be toast..honestly would replace both as l know what yer gona run into..in all honesty best to replace than try to repair..front fenders and inners are cheap...boxs are cheap and plentyfull...LMC for cab corners and door rockers..local pick a for assorted small parts and SEM paint for rest

Ya, its gonna be a serious job. Hopefully the budget will be big enuff to do it right. Thanks for the input. Rockers are great on top, but you guessed correctly, bottoms are history!

[cancritter]

all 3 of my obs trucks all had similar rust issues..once you know where they are its easy to control...rockgarded my inners ect to prevent rust ect...wouldnt worry about time frame for completeion..will be done when its done budget provideing...going into my 5th year with my build and lots here are in same boat..take your time &do it right...dosnt have to be the best but do it right and it;ll outlive ya

[Andrew.]

frame off..blast frame...replace cab corners and rocker panels under doors..will gareentee thier toast by pics..round up new box and front fenders..chances bolts holdin inner to outer will be toast..honestly would replace both as l know what yer gona run into..in all honesty best to replace than try to repair..front fenders and inners are cheap...boxs are cheap and plentyfull...LMC for cab corners and door rockers..local pick a for assorted small parts and SEM paint for rest

thisx 10000000000

if your panels look like that, your frame is gonna be a disaster, especially all the places salt/dirt gets trapped. Leafs, hangers, inbetween frame rails etc. Take your time, do it right.

[skaneever]

Thanks for the info guys. The budget will make it a slow process, so I'm definately gonna do my best to do it right.

[themagicdustman]

Where in upstate are you located? Might not be too far away. Good luck with the repairs. I have to a bit of repair on mine also.

[skaneever]

Where in upstate are you located? Might not be too far away. Good luck with the repairs. I have to a bit of repair on mine also.

Tupper Lake. Quite a bit north of you, but you know how the salt is!

[PA.REDNECK]

It's much easier and better to replace rusted parts then try to repair them, unless its just bery small. In you case however i would replace cab corners, rocker panels, bed, and fenders. While you have the truck torn apart you might want to go the extra mile and sandblast and paint the frame, judgeing from your pictures its probably rusted badly, might as well do it right the first time and not have to go back and do it again later. Once it is all fixed, wash your truck often to prevent the same issues from happening again, don't just wash the outside of the body eiither, be sure to get the usual rust spots as well as the inner bedsides and underneath

[JBecker]

frame off..blast frame...replace cab corners and rocker panels under doors..will gareentee thier toast by pics..round up new box and front fenders..chances bolts holdin inner to outer will be toast..honestly would replace both as l know what yer gona run into..in all honesty best to replace than try to repair..front fenders and inners are cheap...boxs are cheap and plentyfull...LMC for cab corners and door rockers..local pick a for assorted small parts and SEM paint for rest

+1 on this. I would say try to source a used bed, fenders and doors in good shape. Get cab corners and rockers from lmc, measure, measure, cut, spot weld, grind, bondo (if needed, if done right you shouldnt need bondo). I have a rust free set of fenders and inner wheel wheels if you are interested!