One of my excursions that grew up in Maine has gotten a little cancer. I'm trying to fix it.

It has been caught early but I'm debating with myself on how to properly fix it.

1) remove all rust and weld in patches.
2) buy cab corner/ c pillar for the crew cab pick up and cut out lower c pillar, and weld in replacement.

Any suggestions?
Right rear quarter panel
Right rear lower c pillar

 

I'm fabbing up new ones for my truck along with the rocker panels. Bought rocker panel extensions but the cab corners will be made custom.

 

Wouldn't this work for my situation?

 

NOPE, crew cab cab corner will not work.....without modifications which I cannot do.

Part of inner rocker was bad too.

Ended up buying a used 1/2 quarter panel. It came with half the outer and inner rocker. Which is exactly what I needed.

$300 shipped to my door. Now I just have to weld everything in place and spot puddy and paint.

Darn 40 hour fix for a few small rust holes.....oh yah the $400 bill for paint, quarter and supplies.

It ends up that those little rust holes cost me $400.

 

Well all rust is gone!!

Installed 1/4 of a rust free quarter panel, and inner rocker along with a new outer rocker and painted and clearcoated.

Thumbs up for Spraymax 1K and 2k paint and clear coat. It's GREAT.

 

Great job!

 

Another great product is 3M structural body panel epoxy. It works great and seals the rust prone areas.

It's never coming off though....without a cutoff wheel.

 

Can you only use it where you can get a clamp on it from both sides? Could you use metal screws to clamp the prices together then cut off the ends of the screw?

 

True...I used it on inner rocker.... Large c clamps and several vice grips.

Quarter panel on area where it hooks to inner rocker and the area right in front of rear wheel. Used 8 clamps for that. The outer rocker was easy as you can clamp top and bottom.

There were no areas in my repair that I could not get clamps. But I would assume a screw would work in areas a clamp won't work. I did have to weld the spliced area between old quarter panel and the new panel...it in photo but I dont think you will see it. I was really anel in that area.....did not want it to look any way but new.

If you look closely at finished photo you can see where I cut the spot welds out of the donner panel.....they are full of structural epoxy not welded.
You can also see the epoxy that was pressed out of the square hole on the rocker panel.

The rest was welded.

The photo does not give the repair justice. The lights make it look like there is a bad spot on the left side of photo. There is not it's perfect.

Again this was done with a rattle can! !!!!!
Its in my opinion just as good as a paint gun.
SPRAYMAX 1K paint matched to FU paint code and SPRAYMAX 2k clear coat.....I did entire quarter panel and rocker.

 

Looks like you did a great job there!!

New Guy here getting ready to replace slightly rusted outter rockers just like you have done. Just want to clarify... you drilled out spot welds(already have a spot weld cutter) and used the 3m epoxy to reattach the new outer rocker without welding? I am interested in this as my welder is currently being borrowed by a family member who is 6 hours or so away and want to get this repair done. No structural issues with the epoxy vs welding?

 

This is what it looked like prior to cutting off rest of quarter panel.
I used a structural epoxy made for panels. Says it's got a 4000 psi shear strength. Dp420 by 3M. Given the amount I used I think it's bether than spot welding 10 or so places as the whole thing is epoxied.

For rocker it got about 60 inches of surface about 1 inch wide = 60 sq inches. X 4000 == ALOT 240000 pounds.

I have no complaints at 1/2 that.

Yes I drilled out spot welds. There will be 4 at each end that attach outter rocker to quarter and center rocker. And about 15 or so more on top and bottom lips of rocker.

Then it will pop off....the good thing about epoxy is no sealant needed at joints.

 

Excellent info, thank you.