The beginning of the end.

[custom10nut]

I’m finally starting to find my truck.
Earlier this year, I ordered everything I needed to complete my truck, to include a Disc Brake conversion kit (son and I installed it in April, when he was home on Leave).
I’ve been insanely busy for the past four months, but now I’m making time to work on the “The Truck”.
Yesterday and today I measured, traced out, and cut out the patches I need to repair the few spots of rust.
Really, it needs eight small areas on the two Rockers, and one on each lower Kick panel, so I’ve decided to just cut out the bad and butt weld the new into place.
I’m asking here, for anyone that has done this, are there any “must do” things I need to know about?

[Roostre]

Originally Posted by custom10nut

I’m finally starting to find my truck.
Earlier this year, I ordered everything I needed to complete my truck, to include a Disc Brake conversion kit (son and I installed it in April, when he was home on Leave).
I’ve been insanely busy for the past four months, but now I’m making time to work on the “The Truck”.
Yesterday and today I measured, traced out, and cut out the patches I need to repair the few spots of rust.
Really, it needs eight small areas on the two Rockers, and one on each lower Kick panel, so I’ve decided to just cut out the bad and butt weld the new into place.
I’m asking here, for anyone that has done this, are there any “must do” things I need to know about?

Make sure you cut enough metal out around the rust holes, don't try to save too much. It's very frustrating to be welding along and suddenly burn through a thin spot you thought was good. It's also a lot harder to cut more out once you have the patch partially welded in.

[custom10nut]

Originally Posted by Roostre

Make sure you cut enough metal out around the rust holes, don't try to save too much. It's very frustrating to be welding along and suddenly burn through a thin spot you thought was good. It's also a lot harder to cut more out once you have the patch partially welded in.

Thanks for the tip.
I did go “oversized” with my patches for that very reason.

[Richard]

I personally took the same route on the rockers, kick panels and floor in my truck. Only using the parts of patch panel needed. We do this at the shop as well. I do not understand the value in using an entire patch panel if it is not needed. There are some pics in my build thread on rockers post #30. Some on the cab corners earlier than that. Cutting out a larger area is good advice. But using the whole panel just because not so much imho.

[57taskforce]

Originally Posted by Richard

I personally took the same route on the rockers, kick panels and floor in my truck. Only using the parts of patch panel needed. We do this at the shop as well. I do not understand the value in using an entire patch panel if it is not needed. There are some pics in my build thread on rockers post #30. Some on the cab corners earlier than that. Cutting out a larger area is good advice. But using the whole panel just because not so much imho.

Couldn’t agree more, I always leave as much factory metal as humanly possible while cutting all the rust out. I try to leave all factory body lines as much as possible too because a lot of times the aftermarket stampings aren’t as accurate as the oe stuff. Blending patched and factory body lines together can be a real pain.

[MikeB]

Originally Posted by Richard

I do not understand the value in using an entire patch panel if it is not needed.

I replaced both rockers 25+ years ago with GM parts. The value to me was not having to weld sheet metal. Also not having to worry about more rust in 30 year old panels (50 years old now) coming through a few years later.

[custom10nut]

So, an update for y’all.
Today I cut out three of the bad areas and trimmed my patches, to make the butt welds smoother. I have two more to cut out and refine on the driver side, but compared first three (location was the main issue, and being able to cut), they’re going to be petty straight forward.
One thing I learned today, is that the Factory sure liked to use spot welds to mate the outer Rockers to the inner panel.

I do have one question for the experts:
Are there any spot welds to mate the bottom of the Inner and Outer panels?
I won’t have time to do anything on it tomorrow, but I’ll be back at it on Thursday.
My plan is to have All patches welded in by the end of the weekend.

And one final thought.
It’s a great feeling to finally be finishing my truck.

[custom10nut]

Quick update:
Driver side: all ready to start welding in the patches (5)
Passenger side:two areas cut out, will do the last one tomorrow.
After I go the one all cut, I sat the patch in place, and found that I cut the area two large for the patch.
To quote Winnie the Pooh, “Oh Bother”
No biggie, as fixing this will allow me to perfect my Butt welding skills.
Live an learn
I’m going to take some pictures before I start tacking the patches in place

[custom10nut]

Okay, I’m a little slow.
I finally figured out how to post pictures from my phone, so now I can take update pictures along the way

[Roostre]

Looking good. Are you going to do anything to protect the inside of the rockers since you have convenient access holes right now?

[custom10nut]

Originally Posted by Roostre

Looking good. Are you going to do anything to protect the inside of the rockers since you have convenient access holes right now?

I’m brush coating all the insides with a “Rust Converter”, then when I get it all done, I’m going to get one of the Undercoat kits from NHOU, to coat all the insides after welding.
I’m not too worried about rust, as I’m in Tennessee (they rarely use salt in the winter), and the truck rarely comes out in the wintertime anyway.
It hasn’t seen even a drop of rain in 4 years.