Pillar Rust -- Fixable?
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Pillar Rust -- Fixable?
Anybody had rust around the outside of the windshield on the pillars? The rest of the body looks nice, but this pillar rust looks very expensive to fix. I'm afraid it may compromise the integrity of the cab, and the only way I can see to fix it would be to cut out the rusted parts and weld in new ones, expensive. I think it is going to be hard to justify spending large amounts on a truck this old. Sad to say, but it may be time to retire the old girl. Any ideas?
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Joined: Jun 2001
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From: Loveland, CO.
That's a bad spot. I would not get involved with a vehicle with rust there. However, it can be easily fixed by cutting the pillars out and welding rust-free pillars in. If you know how to do that type of work, it would be pretty cheap, pretty much just the cost of the sheet metal. If you have to pay someone to do it, it could get spendy.
I don't know if it will affect the integrity of the cab that much, it depends how bad it is. If the truck is very nice, it may be worth fixing it properly. If it is not your primary vehicle and sort of a beater, you could just cut the rust out and fix it with body filler, you'd probably have to re-do it every couple of years though. I personally do not like any body filler in my vehicles, especially in a spot like that; but for a non-primary vehicle it would work.
I don't know if it will affect the integrity of the cab that much, it depends how bad it is. If the truck is very nice, it may be worth fixing it properly. If it is not your primary vehicle and sort of a beater, you could just cut the rust out and fix it with body filler, you'd probably have to re-do it every couple of years though. I personally do not like any body filler in my vehicles, especially in a spot like that; but for a non-primary vehicle it would work.
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From: SE Texas
I agree, the A-pillar and top of the cab around the windshield is a tricky area. If it's a small spot, I would just sand off the rusted metal and use some body filler or puddy to smooth it out. If you have to cut thru the pillar and weld in new metal, it will need to be precise for the glass to fit and seal properly. I had a 92 truck in similar shape afew years ago. After some closer inspection, the rust had spread out under the paint all the way on top of the cab. Selling it was my decision, too.
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Joined: Jun 2001
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From: Loveland, CO.
When I was recommending the removal and replacement of the pillar and sheet metal, what I meant was to cut the whole roof off and weld in a new roof from a donor vehicle. Most Broncos (and trucks in general) that end up in the boneyard have major front end and frame damage, because people fix them otherwise. But unless the vehicle was rolled, the roof is usually good. It would cost about the same to get a whole roof then just two pillars, and you would have a perfect seal for your windshield.
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Pillar Rust
Thanks for the advice. I've decided to trade her in or sell her. Heresy I know, but I'm thinking about getting one of the new Tacomas. Can't say enough good about the old Bronco, 265,000 miles, some hard, nothing rebuilt and she is still running. There will be a tear in my eye when I let her go.
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