Body rot
Post Fiend
Joined: Feb 2009
Posts: 8,005
Likes: 7
From: Ottawa, Ontario
^^^ Thats probably because you used a patch panel, and it was welded right over the old rusted one.
You can use patch panels with success, but you need to cut the old rusty one off first, or the old one will affect the new one.
If the rest of the box is clean, or clean enough to justify putting money into it, have a patch panel welded on the fenders, and make sure, you or a body man cuts out the old one first!
If not, find a whole clean box. A couple wires, and 6 bolts and that box comes right off!
You can use patch panels with success, but you need to cut the old rusty one off first, or the old one will affect the new one.
If the rest of the box is clean, or clean enough to justify putting money into it, have a patch panel welded on the fenders, and make sure, you or a body man cuts out the old one first!
If not, find a whole clean box. A couple wires, and 6 bolts and that box comes right off!
Fleet Mechanic
Joined: Nov 2011
Posts: 1,823
Likes: 43
From: New York
It kinda depends on how "pretty" you want it to look. The anti-pretty approach I took was to cut back the cancer to good metal, thoroughly power-wash the area, treat with acid, prime with 7769 Rust-Oleum, and then top-coat. Leaving it this way I've left open an "access channel" to power-wash the area in both direction. I've considered adding plastic wheel arches to hide things but as of yet I haven't. It's not a show-truck after all. 
More Turbo
Joined: Oct 2012
Posts: 639
Likes: 2
First Bondo is not a fix and will fail shortly. Three options.
Replace the bed.
Cut away all rotted metal. Weld in replacement panel. I was looking at using a front fender lip as a donor. New steel must be protected inside and out by paint, or spraying oil, etc.
Cut away all rotted metal. Replace missing section with fiberglass. Spend lots of time getting the lines right. Won't rot there again but may delaminate from the steel someday.
Replace the bed.
Cut away all rotted metal. Weld in replacement panel. I was looking at using a front fender lip as a donor. New steel must be protected inside and out by paint, or spraying oil, etc.
Cut away all rotted metal. Replace missing section with fiberglass. Spend lots of time getting the lines right. Won't rot there again but may delaminate from the steel someday.
Posting Guru
Joined: Sep 2006
Posts: 1,781
Likes: 1
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Posting Guru
Joined: Sep 2012
Posts: 1,949
Likes: 7
It kinda depends on how "pretty" you want it to look. The anti-pretty approach I took was to cut back the cancer to good metal, thoroughly power-wash the area, treat with acid, prime with 7769 Rust-Oleum, and then top-coat. Leaving it this way I've left open an "access channel" to power-wash the area in both direction. I've considered adding plastic wheel arches to hide things but as of yet I haven't. It's not a show-truck after all.
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Posting Guru
Joined: Jan 2013
Posts: 1,933
Likes: 0
From: VA
It's not that it's physically difficult, but it's hard to make it look the same as it did stock and get it perfect. It can be done well, but if you've never done it then it may be hard to get right on the first try.
Personally, I'd rather replace panels than fiberglass or patch panels. If it's not a pretty truck, then I guess it doesn't matter. I guess I'm just a bit particular. If I know of a flaw on my truck, that's the first thing I'll look at every time I walk by it.
Personally, I'd rather replace panels than fiberglass or patch panels. If it's not a pretty truck, then I guess it doesn't matter. I guess I'm just a bit particular. If I know of a flaw on my truck, that's the first thing I'll look at every time I walk by it.
Thread Starter
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Junior User
Joined: Jan 2013
Posts: 87
Likes: 0
Yeah me to. I heard about expanding foam insulation and trimming it when it's still wet. It just needs covered up and I don't really feel like replacing the whole bed it's got a roll bar with KCs and I don't want to wire that up again. Course it would make them brighter.
Posting Guru
Joined: Jan 2004
Posts: 2,403
Likes: 4
From: Charlestown, RI
Expanding foam will make the rot worse than it is. If it's a beater truck and you just want to make it look a little better, then that will work fine. But it won't last.
If it's a truck you're planning on keeping for a long time and the rest of the bed is in good shape, replacing the entire bedsides is the way to go.
If it's a truck you're planning on keeping for a long time and the rest of the bed is in good shape, replacing the entire bedsides is the way to go.
i ain't rite
Joined: Mar 2005
Posts: 65,448
Likes: 5,518
From: Marlboro Mental Hospital.
if you are going to use expanding foam as a base, you need to use closed cell foam. if you use open cell foam it will act like a sponge and absorb water and always stay wet.
Posting Guru
Joined: Feb 2013
Posts: 1,555
Likes: 1
^^^ Thats probably because you used a patch panel, and it was welded right over the old rusted one.
You can use patch panels with success, but you need to cut the old rusty one off first, or the old one will affect the new one.
If the rest of the box is clean, or clean enough to justify putting money into it, have a patch panel welded on the fenders, and make sure, you or a body man cuts out the old one first!
If not, find a whole clean box. A couple wires, and 6 bolts and that box comes right off!
You can use patch panels with success, but you need to cut the old rusty one off first, or the old one will affect the new one.
If the rest of the box is clean, or clean enough to justify putting money into it, have a patch panel welded on the fenders, and make sure, you or a body man cuts out the old one first!
If not, find a whole clean box. A couple wires, and 6 bolts and that box comes right off!