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I just started working on my 86 F-150 last night after a year long hiatus. I figured that I would start with the bed. It has the usual rust above the wheelwells and behind the wheels along with assorted smaller bubbles on most of the bedside. I figured that I can order some patch panels for the wheelwells and for behind the rear wheels, but my main concern is the small areas that are bubbling. I've sanded the bubbling areas to the point that they are smooth and sanded around them until I found clean sheet metal. What are the best options for the next step. I can still see some traces of pitting / rust where the bubbles were. Do I continue to sand to the point where there is not pitting / rust, or can I just prep the surface with a rust converting primer and then shoot the whole bed in epoxy primer for a waterproof coating prior to paint. Or, should I start making patch panels and cut out every pitted / rusted area on the bed and weld new panels in? My fear is that the rust will come back immediately once I paint.
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As long as the metal hasn't rusted through or the rust hasn't created a structural weakness, it's an easy fix.
Clean out all the rust you can.
Treat the area with a rust converter like Metal Ready, Rust Mort, & etc.
Paint with epoxy primer.
This is the standard treatment for rusted areas (assuming you don't put in new metal). Many have gone before you. Many have had great results. Although there can't be a 100% guarantee it won't return, with proper prep & treatment, you should get excellent, long lasting, results.
By the way, patching is called for, when you have rust-thrus. It's the only way to be sure rust and moisture can't attack from the backside.
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