01 excursion 7.3, typical oil pan 7.3 rust. Heavy pack rust on the bottom of the sump portion in right front corner
picture looking from the front toward the transmission you can see the pack rust where it has been seeping oil

Last year I ordered a fiberglass repair shell from these guys
a guy I know let me use his lift, thank you, to do this. So drained the oil, pulled the starter, pulled the flywheel dust cover, then started chipping the heavy pack rust off. Unfortunately the front of the pan is almost as bad so probably in a year or so (hopefully not sooner) will have to replace the whole pan. After and hour or so of scraping and chipping I used various sanding/grinding tools to get the pan cleaned up the best I could. unfortunately the front of the sump up to the cross member is hand sanding. Here are some pictures of the hole and sanded pan
hole is upper right in picture

same hole different angle lower right

bling of the shiny sanded old pan

there is a two part epoxy you mix up and paint the pan and inside of the shell with, then push it up. you will need a jack or a screw type jack and some wood to push up on the pan to help it seat because of the epoxy and to hold it in place while it cures. They say 30 hours to cure at 70F. I let mine set for 48 because it was cooler the past couple days. Here is a picture of the shell on with pressure pushing up on it


filled it with oil last night and moved it out of my friends shop and parked it.

Here is a picture of the front of the pan


Hope to get a year or so from it before total replacement.

I know not the "correct way", that will follow in the future.

 

I have seen that video too. Not a really bad idea actually. Mine is OK right now but If I end up with a leak and I am sure I will at some point I might give that a try. If it gets a truck to the point where the engine has to come out for something else anyway then it did its job.

 

By the looks of your work, I think the bottom sump will be fine. Stinks about the upper area though...

I know of a truck near me that's had Damian's pan saver for over 8 years. Temporary?

I did the same thing to my truck about two months back... https://www.ford-trucks.com/forums/1...-pan-woes.html

 

i did the same thing about 3 months ago, so far its working great. i would suggest going back under the truck and finish sanding the front, then brush on a couple good thick coats of paint. i also took some of the excess ooze and smeared it around on some of the questionable area's.

 

You did a good job on yours. The excursion has 140k+ on it also.
I thought about it but I didn't want to cover the rust, usually accelerate it quicker for me.

 

I think temporary was the key word. Looks like a lot of oil dripping off the front cross member. Must be I scraped too much scale off the pan. Too bummed right now to investigate