Rust Issues

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If you're really fixing it up I guess you'll want to weld it and make it nice.

But I just took an 87 4Runner in similar shape and cut squares around the rust, pop riveted in aluminum, and bondo'ed overtop of that. It turned out solid, with the stiff aluminum backing and the bondo on top.

Make sure you use aluminum rivets, too, or they'll rust and let your sheet pieces loose.

Of course, it's up to you how much you smooth it out over the rivets. I left the 4Runner rough, and put plenty of paint on top.

Won't last forever, but then nothing does. And it was dirt cheap.

Frame is an issue. I'd start laying the oil to it.
 
I think a lot depends on geography. I believe near the ocean roof/gutter rot is common. In areas where they salt the roads in the winter (like where I live) rust attacks the lower parts of the truck, and mostly behind the front wheels (salt spray kicked up by the tires), and the tops of the truck are close to spotless.
I thought that may have been the case I just havent seen many pics on here with the rust the way i have it in my roof .
 
If you're really fixing it up I guess you'll want to weld it and make it nice.

But I just took an 87 4Runner in similar shape and cut squares around the rust, pop riveted in aluminum, and bondo'ed overtop of that. It turned out solid, with the stiff aluminum backing and the bondo on top.

Make sure you use aluminum rivets, too, or they'll rust and let your sheet pieces loose.

Of course, it's up to you how much you smooth it out over the rivets. I left the 4Runner rough, and put plenty of paint on top.

Won't last forever, but then nothing does. And it was dirt cheap.

Frame is an issue. I'd start laying the oil to it.


I think I'm going to skip out on the sheet metal welding and do a little epoxy and fiberglass action...we'll see how the first hole turns out.

My frame is ok. There was one section that I cut out and welded in a new piece. The rear cross memeber has some issues which I had welded when I was on a road trip. Other than that, it's pretty good.

Man RockDoc, my roof is pristine compared to that rig in your link
 
Here are some pics of mine these are passenger side driver side similar I have not had time to upload all of them
pre purchase pic
4343535.jpg

passenger side rust
roofrust1.jpg

Passenger side above doors
roof4.jpg

inner panel repair
roofrust2.jpg

outer rear repair
roofrust3.jpg

inner repair passenger side above doors
roof5.jpg
 
$50 a door and I bet ups shiipping would be around $30 each striped of glass:grinpimp: but let me know:hillbilly:

If my fiberglass creation turns out to be a disaster, the I may consider it. We'll see in a few days.

wengejor
 
rumchaser...did you use a mig welder?
 
Holee blue fj Bat Man!

LOL Just kidden. I wish I had your problem. Mine has a little less body rust, but the frame is shot. Oh well 700.00 and it runs pretty good. Anyway, If you can stick weld you will have no problem with a Mig. I would get some metal and go at it. Whats to lose.
Good luck...........
 
Haha, here is the status of my arts and crafts project. I have a few more layers of fiberglass to go before I can start with the bondo.

RUST_6.webp

Not the most beautiful but the epoxy gets real hard and it's not going anywhere.

I did a little bondo action on some of the smaller rusty areas.

RUST_7.webp


Here's the end result on the fender. I think I need to sand it a little more to get the lines out of bondo...first time using the stuff, so I'm still learning.

RUST_8.webp
RUST_6.webp
RUST_7.webp
RUST_8.webp
 
Very interested to see how the fiberglass works out for you wengejor, looks like you are a few days or weeks ahead doing exactly what I'm planning.

Did you treat the rust with phosphoric acid?
 
No, I didn't get phosphoric acid...perhaps I should before it's too late. I just used the grinder to get rid of the chips and go almost down to bare metal.

Here are some more pics. I picked up an orbital sander which makes the bondo sanding go much quicker.

Finished the rear pass door corner and the wheel well.

RUST_9.webp

I re-did the front fender and it looks much better now.

RUST_10.webp


The fiberglass patch is still curing and I will soon be able to trim it with the cut-off wheel and then start with bondo. There are at least 20 layers of fiberglass.

RUST_11.webp
RUST_9.webp
RUST_10.webp
RUST_11.webp
 
Looking really good so far. Is your fiberglass the woven cloth, or the thicker random "mat" of fibers? I got the mat stuff, but maybe I should have some of each.
 
Lookin Good

Well, it looks better already, keep us posted...
 
I have both the random mat type as well as several types of structural grid. You can get the structural stuff at Lowes or Home Depot along with some epoxy.

I just trimmed it with the grinder. I am going to put some more layers on and make it a little nicer before going to bondo. I think I'm pretty happy with the progress so far.

RUST_12.webp

RUST_13.webp

Thanks for the inspiration along the way!

wengejor
RUST_12.webp
RUST_13.webp
 
I don't mean to be a downer so much, but IMO, all that work will be trashed within a year or so if that rust was left untreated before 'glassing. Now, if you want to treat the work as a simple learning project, then I'm all for that, but if you are expecting a long-term solution I think you'll be bumming soon. Even treated, any remaining rust will still rear it's ugly head eventually.
If you aren't cutting back to sound metal, I say stop now, remove the glass you've done, and use phosphoric acid wash along with a quality rust abater like Rust Bullet, Zerorust, etc.

For the rockers, I vote to chop them as much as you can to eliminate the rust, and gain a little body clearance for off roading.
 
Ok, I'm done for today. Here's the current state of the arts n crafts project.

RUST_14.webp

RUST_15.webp
RUST_14.webp
RUST_15.webp
 
I don't mean to be a downer so much, but IMO, all that work will be trashed within a year or so if that rust was left untreated before 'glassing. Now, if you want to treat the work as a simple learning project, then I'm all for that, but if you are expecting a long-term solution I think you'll be bumming soon. Even treated, any remaining rust will still rear it's ugly head eventually.
If you aren't cutting back to sound metal, I say stop now, remove the glass you've done, and use phosphoric acid wash along with a quality rust abater like Rust Bullet, Zerorust, etc.

For the rockers, I vote to chop them as much as you can to eliminate the rust, and gain a little body clearance for off roading.


Ok Wile, thanks for the heads up. I'm going to pick up some phosphoric acid wash and some rust bullet. I'm not trying to make a garage queen, just want to impede the inevitable death by rust.
 
Sorry to be a buzz kill but unless you cut out all the rust it will come back. Painting w/ Rust Bullet or POR15 (or similar) will work for a long time but probably not forever. Simply grinding off mostly to bare metal and glassing will allow the rust to come back. If its just a beater and/or wheeler then its not a problem - if you want something more I would suggest cutting metal out and/or buying panels.

The rust is always worse than you think.

Those rear wheel well lips have rust inside the layers of metal - the rust will come back from between the layers.

I have a Pig - I know rust!

:beer:
 

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