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Old 09-11-2017, 02:25 PM   #3
72HuggerK20
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Join Date: Sep 2016
Location: Titonka, IA
Posts: 112
Re: Welding/Repairing Rust 01 Sierra

We never do those replacement panels anymore. With the time you have into them, you're better off doing the whole box side. Then you know what you've got. But since you're looking to sell it, and if you don't care about your time, go right ahead. I would highly suggest pulling the box off the pickup. It only takes an hour to take out the bolts, undo the wiring, take the filler neck loose, and take the tailgate. Then grab a few buddies to help lift it off. If you still don't, tape up the filler neck very well. Unhook the ground on the battery. Make sure you undercoat the **** out of the inside of everything when you get the old piece cut out. Weld through primer anywhere you will be welding. Trim up your patch to the general shape you want (you almost never need the whole thing, better to keep the repair small. But still cut out ALL of the rust). Then make the hole fit the patch, not the patch fit the hole. It'll save you a lot of time. Make the patch so that it'll lap behind the original panel. It'll be easier to weld, and reduce warpage. The height difference will be made up with filler. As far as safety, make sure you have safety glasses, a good welding helmet, welding gloves, and a good dust mask when sanding filler.
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