How To: Ruin a Perfectly Good K/5

[68Timber]

Dang that's a nice looking repair. My 85 has the same rot in both corners, I get to do this repair soon.

[gringoloco]

...and done. Including the big, boogery factory style weld holding the bedside to floor

[gringoloco]

Originally Posted by 68Timber

Dang that's a nice looking repair. My 85 has the same rot in both corners, I get to do this repair soon.

Thanks, I'm no professional, just try to take it slow and remember it's only metal.

[gringoloco]

Thought I could get away with not cutting the stake post, but the good metal was just a little too deep. This side is going easier than the drivers, partly due to no extra stuff in the way, and partly due to the learning curve.

The cross sill is patched and the floor patch is fitted. Need to punch the plug weld holes and she's ready to burn in. Taking it easy tonight, so I'll weld it in the morning. Thanks for tagging along

[gringoloco]

Done and done. Pass side patch did not line up as well for whatever reason. Took a little extra persuasion to coerce the ribs into alignment. Metal straightened and body-worked the drivers side as well. I'm through with this area until final prep for paint

Looks like it's time to move on to the A and B pillars, which I am not looking forward to. I am, however, looking forward to coating the insides of the rocker boxes in POR--this stuff is addictive

[mcbassin]

Excellent work on the rust repairs Chris. You made that look way too easy

[gringoloco]

Originally Posted by mcbassin

Excellent work on the rust repairs Chris. You made that look way too easy

Thanks, Mike. The pictures don't do justice to all of the cutting/fitting/grinding/welding that goes into the repairs. Honestly, this is my first time attacking rust this extensive; I learned most everything I'm doing here by watching folks like you on this board.

[gringoloco]

Randomly selected B pillar first. I've seen worse...

[gringoloco]

Done cutting(?) for now. Leaving as much of the existing metal as I can.

Rocker box is super solid. Time to POR inside the B pillar, while it's accessible.

[gringoloco]

First patch in and POR'ed: I only ground the welds that have a chance of being seen

[gringoloco]

Built a template for the next piece and burned it in:

[lolife99]

You do great work!

[gringoloco]

Originally Posted by lolife99

You do great work!

Thanks, man. All I know is I do slow work

Finished the outside of the support; still need to work the leading edge then it's ready to be skinned. Looking at these pictures makes me want to grind the welds in there--I need to get it buttoned up soon to quell the urge to perfect it. Ended here for the day:

[gringoloco]

Cut a piece for the front side of the support and fitted a 95% solution for the outer skin:

[gringoloco]

Tack, tack, tack, grind, tack, tack, tack, grind, sand, prime. It needs a little hammer/dolly and a skim coat of filler.

[gringoloco]

Then the A pillar... HartRob, in his Superburb thread, described this area as a five-dimensional puzzle. I tend to agree. Everything comes together in the same place, then traps dirt/moisture and rots it all.

I cut out all of the offensive metal, including floor, inner rocker, kick panel, A pillar, floor support, and a small bit of the rocker box directly under the support. Decided to patch the support, as opposed to replacing it, as there was only a small area gone and the replacements I received are paper thin garbage--I used a scrap of one of the fender patches to repair the existing piece. Followed that with buttoning the rocker box back up, then ended the day with POR-ing as much of the inside of the box as I could reach. Next up: 5D puzzle

[Chulisohombre]

God work

[mcbassin]

You are doing incredible work on the metal replacement. Honestly, it's exactly this kind of series of pictures that made me believe it was easy enough for me to tackle.

I know good and well how much effort that went into the finished product.
Looking forward to watching the rest of the front pillar repairs.

Awesome work as always!

[lks dcvn]

Awesome job! You made that look easy. Having been in those sections before - I know that is not fun sometimes.

[aggie91]

Your work looks good. While I enjoy metal work, doing this kind of work is not at the top of my list.

Keep the pictures coming!

[gringoloco]

Originally Posted by Chulisohombre

God work

Thanks!

Originally Posted by mcbassin

You are doing incredible work on the metal replacement. Honestly, it's exactly this kind of series of pictures that made me believe it was easy enough for me to tackle.

I know good and well how much effort that went into the finished product.
Looking forward to watching the rest of the front pillar repairs.

Awesome work as always!

Appreciate it, man. That's my thoughts, too--seeing others' accomplishments inspired me to tackle the job myself. Hoping to give back a little

Originally Posted by lks dcvn

Awesome job! You made that look easy. Having been in those sections before - I know that is not fun sometimes.

Thanks--your work and others proved to me it is possible. It is a little fun and therapeutic, but can become droning (and time consuming).

Originally Posted by aggie91

Your work looks good. While I enjoy metal work, doing this kind of work is not at the top of my list.

Keep the pictures coming!

Thanks a lot! Not my first choice of things to do, for sure, but the payoff will be huge when it's complete. Pictures will slow a bit, as I'm back to my day job again...

[gringoloco]

Welded some square nuts on the back side of the floor support, like I've seen many others do. Will not have access to inside the rocker box when it comes time to tighten the four bolts through all these sheets of metal. Spent some time bending, shaping, fitting, welding, and grinding the floor patch. Next is the front section of the inner rocker, then kick panel, and finally, A pillar. Once that's all in, I'll be ready for the outer rocker and done with this side

[gringoloco]

...and finished off the floor to inner rocker transition. Still some tweaking to do as I fit the kick panel patch, but it is all coming together...

[thor]

Repairs are looking great! This was already a good looking Blazer. Now it's going to be even better!

[gringoloco]

Originally Posted by thor

Repairs are looking great! This was already a good looking Blazer. Now it's going to be even better!

Thanks, man! This rust has been really bugging me...

Got the kick panel fitted and burned in, then rough first fit on the A pillar. Not super happy with the quality of the pillar piece, but it will be hidden when all is said and done. This 5D puzzle is kicking my ass--hopefully the other side goes smoother...