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Discussion Starter · #161 ·
I finished the body work “for real” today. It’s smooth and straight and ready for base coat in the morning. I finished things up with seam sealer. I brushed it on the seam at the back of the cab similarly to Chrysler. I also applied some over the backside of the welds. I’m expecting that it’ll keep moisture out of the welds, preventing any rust bubbles in the future.





 

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Discussion Starter · #165 ·
I went after the frame rust last night. Removed the tank, exhaust and crossmembers. The damage on the passenger (righthand) side is worse than it looked.




I also found that rust between the frame sections on the driver side is bulging the two apart. The metal on the passenger side rail is now a thin layer of steel which surrounds a thick layer of iron-oxide. The actual steel in this area is probably 1/32" of an inch thick.



So I think the next step is to support the front of the truck, remove the leaf springs and roll the rear axle out of the way. Then grind and drill the rivets holding the leaf-spring mounts and rear crossmember and separate the rear frame rails from the front. There are 16 rivets that will have to come out.



Once disassembled, clean up the contact area on all four sections of frame, weld in new patch panels as needed, and then put the whole thing back together with bolts.

But what do you guys think? Is this the right way to go or am I over complicating it?
 

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Discussion Starter · #166 ·
I have the back frame separated from the front. Not yet lifted out of the way, but separated.

This is what fell out from between the frame rails on the passenger side, once I removed the front spring perch:



And this is a look between the frame rails on the driver-side. I'm glad I decided to do both sides.

 

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WOW! This thing is really becoming a project (You're doing excellent work by the way). Frame rust sucks. I have 3 trucks at work that I have condemned because of frame rust. One is a 2015 F150 and it only has 36K miles. Waiting for approval to send them to auction, but that's probably a month away. Dennis
 

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Discussion Starter · #168 ·
WOW! This thing is really becoming a project (You're doing excellent work by the way). Frame rust sucks. Dennis
Thanks Dennis. Yeah, this one has been a lot of work. The rest of the frame is in really good shape, most of it with the factory black paint still applied, so I think it's worth fixing these spots, even if they are a mess. I did manage to get the rear frame section off of the truck yesterday.





I need to cut out about 18" of frame, both sides, weld in new metal and some fish plates (maybe). I thought I only needed about 12" so my steel plates are too small. No biggie as I can use them for jigs on the mill. While I wait for the new plates to come, I may clean up the rear axle and other parts and give it all a coat of 2k paint. But we'll see.
 

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Discussion Starter · #170 ·
I started repairing the rear section of the frame today. Cut out the rust, cut a patch panel and welded it in. It really wore me out. The driver side section is done. Tomorrow I’ll tackle the passenger side.




 

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Discussion Starter · #171 · (Edited)
Here's the video I made showing the frame separation.


Also, this past weekend, I finished repair on the rear frame section. This weekend, I'll tackle the truck-side frame. I hope it'll go faster as I've learned quite a bit repairing the first two rails. I'll have the second video out shortly afterward. It's about halfway done right now.
 

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Discussion Starter · #173 · (Edited)
Busy day for the Dodge! I got all the rust off the rear axle and gave it a coat of paint. You may think this sounds familiar. That's because it is. I did the same thing back in December of 2018. The paint I used, Rustoleum Self-etch and Professional, failed a few months after I applied it. So I did it again. Took a few hours with a needle scaler and a cup brush to get it back down to clean metal. This time, better primer, 2k chassis paint.






I also cut out the rust and welded in a patch on the passenger-side front frame. I have the two frame halves back together, temporarily, to make sure everything fits.





I'm beat to crap. I think my legs are getting too old for me kneeling on them all day. Hopefully later this week, I can get the driver-side done.
 

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That's some nice work, looks great!
 

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Busy day for the Dodge! I got all the rust off the rear axle and gave it a coat of paint. You may think this sounds familiar. That's because it is. I did the same thing back in December of 2018. The paint I used, Rustoleum Self-etch and Professional, failed a few months after I applied it. So I did it again. Took a few hours with a needle scaler and a cup brush to get it back down to clean metal. This time, better primer, 2k chassis paint.

Agree, great work. I always thought that rustoleum was a good product. At least it looked good the first time, but if it didn't last, well that's the true test of a product.
 
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