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I am torn so I will toss it to you to help me decide.
About a month ago, I bought a 2001 Limited V10 4x4..with out looking or test driving. (I know...and now I am kicking myself in the butt). Did not think it would be too bad of a project and it checks all the boxes for what I am looking for.
I have already repaired the rear lock actuator and the shift indicator. I have more parts coming in for the shifter because its still a bit sloppy. I also have various gaskets and tune up parts coming.
Last week I went under the vehicle and found a lot of rust. The rockers on both sides will have to be replaced...(was thinking of letting a shop do it because I do not have a welder) I will also either need to sand blast the underbody or get under there with sanding stuff myself.
I am thinking that I should just sell it and get one that does not need to have as many repairs. I do have a budget and a time schedule. with this virus thing, it has put me behind. I am looking to have a vehicle 100% road/trail worthy by beginning of june and start my journey by mid june.
I love the vehicle but feel like I might be in over my head and not have time or money to make all the repairs by Jun 1.
Anyone know how long it takes to manually remove rust from underbody?
Cost of a shop installing rockers? or would it be cheaper for me to buy a welder, learn to weld and do it myself?
Don't know where you are located but unless you are in the rust belt also known as the Midwest the rust you have to deal with probably isn't severe enough to inhibit being driven. And even then unless the body mounts are rotten or the doors have holes it still is drivable. Outer rockers can be done without welding. Inner rockers not so much. Mine looks almost identical to yours and mine has pretty significant rust. Rockers are gone. 3 out of the 4 door bottoms are gone. I am planning on taking the summer and fixing it all a little bit at a time . Can't have the vehicle unusable for more than a day or two at a time so little bit at a time is all I can do. Also with the coronavirus shutdowns where I am at, auto body shops are not considered essential so they are not open.
Tell us some about your trip as well. I would not worry too much about the rust unless you feel the floor pans giving way, especially if you are on a schedule. While it will get worse...it probably won't fall apart for years to come.
Since this is an Excursion enthusiast forum, we might be biased toward keeping it. Take a class at your local JC and learn to weld; it's a skill you can always use.
I would look at the safety systems first. How are the brakes, front suspension and steering linkages. That picture looks real good. Maybe you should bring it to your mechanic for an honest opinion of its repair needs.
Welding sheet metal isn't really easy but it isn't really hard either. I make do with a mig machine from harbor freight. I have a mix gas bottle and don't use flux core wire. I've also been welding since I was a teenager. I wouldn't say I'm good at it but with some grinding and bondo my sheet metal welding will pass...
Depending on how deep you're in it financially would influence my decision. Can you sell it for a profit, sell it and break even, or sell it and loose money? Regardless of the answer to that question, can you afford to replace it if you sell?
Underbody rust doesn't necessarily have to be totally removed. Rust through on the rockers would be nice to have fixed but doesn't usually cause moisture intrusion to the cabin.
May be best just to drive it as it. I have done some sheet metal welding on my Ex and the metal is THIN and difficult to weld IMO...
Take a class at your local JC and learn to weld; it's a skill you can always use.
