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I have a 77' ford extended cab that is completely rusted out just underneath the extended cab. It got so bad that I took a grinder and cut the bottom half right off and rebuilt the panel with fiberglass. But the fiberglass keeps cracking and I'm tired of repairing it. I had tried to weld thin sheetmetal on it with a mig welder but it just burnt through. Does anyone have any ideas on how I can fix this?
As i type this i believe these panels are not being made as of now right?
What i would do is this;
buy door patch panels and use them for your new rocker on the extended part.Use epoxy paint on the back side and or undercoating,that can burn pretty god though when you weld them in.I do stuff like this all the time.But!I havn't tried the door idea.Someone else told me they knew a guy who used doors for the panels.Also install some kind of flap or somthing in front of the ex cab portion or small flaps behind the front wheels.
Hope i helped?!
...blue