More sheetmetal madness. This is another known problem area for corrosion on Squares , the roof area above the doors / jamb. Here is the worst one on my dually , its the drivers side door. This is due to leaking drip rails. You may see corrosion where pillars attach to roof as well. This area has two layers of sheetmetal. I cut out the outer then proceeded to remove the inner as well. Sent from my iPhone using Tapatalk
The bad inner sheet metal cut out with angle grinder cutoff wheels 4 1/2 “ Sent from my iPhone using Tapatalk
I wanted to lead the patches around the windshield but haven’t had good luck with it. Idfk what I’m doing wrong. Tins up nice but lead doesn’t bond well. So it’s bondo for me. You’re a real man if you can take that truck through the woods after you get it finished! Not me I’d cry if I scratched it up. Lol.
Outer sheetmetal welded in and grinded up to where im holding the file. This completes this repair , ready for primer and topcoats. Damn leaky drip rails cause this. When i took the rails off one had an open hole where an assemblyline worker drilled the hole short. Mehhh , just leave it , send it down the line. These trucks were designed to be used , beat to fu—k and junked after 10 years. They never intended for them to last 40 or more years but we have other ideas dont we ? . Sent from my iPhone using Tapatalk
I leaded my left fender using homemade junk instead of buying the correct materials. It worked but was not optimum way of doing it so I abandoned the idea . I’m still interested in trying it with the correct stuff elsewhere. This vehicle is done as far as bodywork is concerned. Ya gotta get em out there and use em so people can see them in action. The day is coming where our scumbag leaders will downright outlaw these vehicles from existence in the name of global warming. Enjoy them while we can. Sent from my iPhone using Tapatalk
This is the drivers side fender. It was destroyed by a leaking windshield wiper fluid tank and $0.10 of hose. I actually bought a replacement fender for $150 which turned out to be a total piece of shit. It was a 1/4” short leaving a door gap over 1/2” wide , unacceptable. So Im forced to repair the superior GM fender. Sent from my iPhone using Tapatalk
The patch trimmed and slowly stretching it to follow the wheelwell curve Sent from my iPhone using Tapatalk
The rust piece cut out next to the new patch. Can you see the curvature developing ? This harbor freight stretcher shrinker works beautifully. HF has its reputation and that reputation isnt fully warranted , its driven by dumb f—ks who dont know what theyre doing or attempt to get cheap tools to do jobs they werent designed to do. I’ve never had problems with their tools knowing I would modify some of them for better performance. These work flawlessly right out of the box Sent from my iPhone using Tapatalk
The curve completed matching original wheelwell radius and the sliver of sheetmetal laying there to fill in the open hole between new and old Sent from my iPhone using Tapatalk
Here is everything all welded in . There is a 4” slit I had to cut vertically to relieve warpage and re weld. Sent from my iPhone using Tapatalk
