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Old 05-12-2019, 11:31 PM   #1
Peanut74
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Location: Prattville, AL
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Order of rust repair

Ok, I got my cab media blasted and identified all the rusted areas. On the left side I need to replace a section of the floor, kick panel, lower pillar post, inner and outer rocker panels. The floor supports seem to be solid and I will confirm that once I open it up.

My question is what is the order I should use to replace the rusted parts?
> Run some 1" tubing braces and just cut it all out
> Replace the bad floor sections then the pillar and then the inner rockers
> Just the opposite the pillar and inner rocker and then the floor sections

For the outer rockers I will weld them in once I have the doors on. Just want to make sure that I don't get the cab out of alignment
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Old 05-13-2019, 09:43 AM   #2
Peanut74
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Re: Order of rust repair

I'm also trying to confirm the door hinge pillars did not move. When I measure just under the dash door seal to door seal I measure 64-5/8". When I measure just above the transmission I get 65-5/8". Could someone confirm this for me, please. It might explain some of the issue I seen when I removed the outer rocker.
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Old 05-15-2019, 09:46 PM   #3
jgr
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Re: Order of rust repair

First douche the entire cap with wax and grease remover blow off and get it in epoxy two nice coats
Some pics would be good, but start with the floor and work your way out to the rockers. I would run a brace from the door hinge area to the door latch area if you are happy with the door gaps always work in sections because if you cut to much out you can get in trouble real fast; also do it while it is bolted to the frame with your new cab mounts.
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Old 05-15-2019, 10:41 PM   #4
Peanut74
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Re: Order of rust repair

Thanks jgr. After I had the media blasted done I got it in epoxy primer. I wanted to make sure it didn't flash rust on me. I already have enough rust to repair.
Like you stated, I was thinking of running one brace from the door latch to the door pillar. Then running another across from one door pillar to the other. Then work on one side at a time. So thanks for confirming that part.

Where I was stumped was do you work from the outside in or inside out. Thanks for confirming that I should work on the floor first and then the rocker and such.

As far as putting the cab on the frame I can't do that right now. After I took the truck apart I found out the frame was bent. So right now I got the cab on a homemade wooden fixture. So would you advise waiting until I have a new frame before doing the floor repair or go ahead and repair the floor while the cab is on the wooden fixture?

I'll post some pictures once I figure out how to do it.
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Old 05-15-2019, 11:51 PM   #5
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Re: Order of rust repair

Quote:
Originally Posted by Peanut74 View Post
Thanks jgr. After I had the media blasted done I got it in epoxy primer. I wanted to make sure it didn't flash rust on me. I already have enough rust to repair.
Like you stated, I was thinking of running one brace from the door latch to the door pillar. Then running another across from one door pillar to the other. Then work on one side at a time. So thanks for confirming that part.

Where I was stumped was do you work from the outside in or inside out. Thanks for confirming that I should work on the floor first and then the rocker and such.

As far as putting the cab on the frame I can't do that right now. After I took the truck apart I found out the frame was bent. So right now I got the cab on a homemade wooden fixture. So would you advise waiting until I have a new frame before doing the floor repair or go ahead and repair the floor while the cab is on the wooden fixture?

I'll post some pictures once I figure out how to do it.
I worked from the inside out on mine. I did a lot of the work with the cab on a metal stand with wheels. No issues with things lining up on the frame. Look at my build (link in my signature) and you’ll see what I did.
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Old 05-16-2019, 07:26 AM   #6
jgr
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Re: Order of rust repair

you should be ok on the wooden dolly as long as you don't cut to much out. if it is possible bolt it to the dolly using the original 4 mounting point's. you will be surprised how much things can shift around. reminder your doors and how they fit will always be you point of reference.
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Old 05-16-2019, 08:05 AM   #7
cleanfreak
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Re: Order of rust repair

The last one I did , I confirmed the frame was straight and bolted it down with new body mounts , with the frame squared up on 4 jackstands. I have not braced the cab before doing this , but put the doors on and off to check gaps , starting with the window area. Order of rust repair that seems correct is floor and inners first , inner kick panel and a pillar repair , b pillar repair , cab corner , then outer rocker.. fitting the door at almost every step. You can adjust the door gap around the window & b pillar quite a bit by not bracing the cab , before you bolt down the A and B pillars , and before welding the kick panels and cab corners.. hope this helps , looking forward to some pics.
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Old 05-16-2019, 09:21 AM   #8
Peanut74
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Re: Order of rust repair

Thanks for the info everyone. I am at the edge of the cliff and when I take the plunge I want to make sure I hit water and not the rocks.

After reading everyone's input I am going to make sure the stand and cab are level with the floor. I have the cab mounted to my fixture at the cab mounts so I'm good on that front. Just need to shim where required to get it level.

As for the bracing if I run it to the inside of the cab I should be able to mount the doors to check gaps. Not quite as solid as running the brace in between the pillars but I believe it should work and still allow me to mount the doors to check gaps. What does everyone think about that plan?
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Old 05-16-2019, 10:03 AM   #9
Peanut74
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Re: Order of rust repair

I think I got it figured out how to upload pictures. Not as easy as copy/paste but I got it to work!!
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Old 05-16-2019, 10:13 AM   #10
rjs53
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Re: Order of rust repair

Not to bad actually. I replaced cab corners, inner-outer rockers, cab mounts, pillars and patched kick panels. I started by replacing inner rocker first cause my floor was solid enough I used it as a line to keep everything in place. I'm sure everyone else has a better way but I figure if it lined up when I started it would line up when I was done, and it did. I also rebuild the door hinge before trying to use it for reference. Just in case it was hanging a little.
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Old 05-17-2019, 09:35 AM   #11
jgr
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Re: Order of rust repair

Looks good I think you are on your way!!
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Old 05-17-2019, 09:26 PM   #12
Peanut74
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Re: Order of rust repair

Well I took the plunge today and started on the drivers side. Cut out the rot on the toe board. I didn't have a patch panel so I made my own and welded it in. Tomorrow I will work on the rust out floor section.
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