The dreaded rust
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The dreaded rust
Hello everyone I hope all is well! I'm a new member and just joined the EX family. I bought an 05 4wd Eddie Bauer off and auction. I was a little leary from the location but bought it anyway. I arrived in Buckhannon WV and they brought it out. It was covered with snow but what I could see looked good and the interior was super nice but then I noticed laying on the running boards chunks of rusted metal.... The outer and inner rockers and one jamb at least need to be replaced. It appears that the inner rocker attaches to a cross member that goes across to the other side under the body. One side of this crossmember piece is rusted as well. What is this piece called? When I research it mostly frame cross member stuff pops up. Any help or recommendations are appreciated and if I'm posting wrong just let me know!
Fleet Mechanic
Joined: Mar 2019
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I just went through this with mine. You can learn a ittle more here and see what all is involved. https://www.ford-trucks.com/forums/1...money-pit.html . Those crossmembers are not available. You can get inner and outer rockers here. They are very high quality. https://www.etsy.com/listing/6674678...2004-2005-ford.
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Wow I'm at work right now so I scanned through your thread kind of quick. You have an awesome ride and you put alot of great work into it! I gotta learn to weld! I appreciate all that good info! I can already tell it's really gonna help me out with alot of my problems and some other things I've been wanting to do like the 4.30s.
Thank you again!!
Thank you again!!
Fleet Mechanic
Joined: Nov 2015
Posts: 1,840
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From: NoVA
Hello everyone I hope all is well! I'm a new member and just joined the EX family. I bought an 05 4wd Eddie Bauer off and auction. I was a little leary from the location but bought it anyway. I arrived in Buckhannon WV and they brought it out. It was covered with snow but what I could see looked good and the interior was super nice but then I noticed laying on the running boards chunks of rusted metal.... The outer and inner rockers and one jamb at least need to be replaced. It appears that the inner rocker attaches to a cross member that goes across to the other side under the body. One side of this crossmember piece is rusted as well. What is this piece called? When I research it mostly frame cross member stuff pops up. Any help or recommendations are appreciated and if I'm posting wrong just let me know!
Oh.....and we are all suckers for pictures and build threads. Mine is linked in the signature below
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Thank you I appreciate that! And I'm greatful for all the knowledge I'm getting here. The downside about buying from an auction was the rust the upside was the price and still went higher than I wanted but maybe have a little money left for those mods you were talking about
. I really like that folks are logging their projects. Y'all got mad skills and it's very informative!!
. I really like that folks are logging their projects. Y'all got mad skills and it's very informative!!
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From: Media PA
Welcome to the EX forum! 
Dealing with serious rust can be a challenge, but also a great opportunity to learn some new skills and acquire some new and very useful tools!
We are going to need some pictures of the good, the bad and the ugly!
Dealing with serious rust can be a challenge, but also a great opportunity to learn some new skills and acquire some new and very useful tools!
We are going to need some pictures of the good, the bad and the ugly!
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Thank you and you are for sure right! I'm about to get a crash course in welding. Got a busy work schedule but hope to start soon and I will post some pics. Any suggestions on the type of welder I should buy. I have heard people say MIG and flux. For small time I thought HF might be good enough at a decent price for this application. I also found this at northern tool. Lincoln Electric Handy MIG Flux-Cored/MIG Welder with Face Shield — Transformer, 115V, 35–88 Amp Output, Model# K2185-1... Would something like this be enough?
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Fleet Mechanic
Joined: Mar 2019
Posts: 1,293
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Thank you and you are for sure right! I'm about to get a crash course in welding. Got a busy work schedule but hope to start soon and I will post some pics. Any suggestions on the type of welder I should buy. I have heard people say MIG and flux. For small time I thought HF might be good enough at a decent price for this application. I also found this at northern tool. Lincoln Electric Handy MIG Flux-Cored/MIG Welder with Face Shield — Transformer, 115V, 35–88 Amp Output, Model# K2185-1... Would something like this be enough?
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I had the same problem when I bought mine out of Illinois. Inner and outer rockers are easy to source. But, I have not been able to find rear c pillar/dog leg in new panels.
The auto darkening shade is a must.
I got the Hobart handler 140 and like it, had an issue with the feeder initially and had to return it for a new one
The auto darkening shade is a must.
I got the Hobart handler 140 and like it, had an issue with the feeder initially and had to return it for a new one
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WE3ZS and Scott Estes thanks that is good to know I was wondering about that! I will be adding to my shopping list. Bad way to have to get new tools and equipment but I likes new tools!! Im also up against the dog leg problem hopefully I can work it out like Dweber85rc did. His was very impressive!
5th Wheeling
Joined: Sep 2020
Posts: 33
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Hi Machine Head,
I had the same issue that you are describing with the "floor pan crossmember" which is the part that you describe as running from side to side. I found the part at Lakeland Ford Online Parts. Upon receipt I had the rusted part cut off on each side and the new part cut and welded to the crossmember part that remained. Not into lifting the body off the frame to replace it completely...and it passed inspection! Here is a link to another vendor that has the part I used on my 2001 V10 (https://www.getoemparts.com). The part number for my ride is F81Z-2510776-AA...pretty sure that will not be yours for your 2005 but I found searches were better when I spelled "crossmember" as one word. Good luck on your rebuild!
I had the same issue that you are describing with the "floor pan crossmember" which is the part that you describe as running from side to side. I found the part at Lakeland Ford Online Parts. Upon receipt I had the rusted part cut off on each side and the new part cut and welded to the crossmember part that remained. Not into lifting the body off the frame to replace it completely...and it passed inspection! Here is a link to another vendor that has the part I used on my 2001 V10 (https://www.getoemparts.com). The part number for my ride is F81Z-2510776-AA...pretty sure that will not be yours for your 2005 but I found searches were better when I spelled "crossmember" as one word. Good luck on your rebuild!
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Most excellent!! Thank you I will be checking that out for sure. I thought I might have to resort to a good ol pick n pull. But some of those have restrictions on cutting vehicles. Very helpful I appreciate all the good Info!
