Author Topic: Daily Driver rust repair  (Read 14512 times)

0 Members and 1 Guest are viewing this topic.

Offline ramcharger422in3

  • Lifetime Supporter
  • RCC Rookie
  • *
  • Posts: 318
  • Gender: Male
  • If you didn't build it, it's not yours
Daily Driver rust repair
« on: February 25, 2011, 01:30:18 pm »
Well here goes... I have been reading and enjoying everyone's projects for a while. I have recently completed the first part of a restoration on my 1988 Ramcharger. An everyday driver for me, and I want the truck to continue to be a solid runner (and beach goer) for many more years. Standard 318 TBI w/NP241 transfer case. I did lift it slightly when one of the stock spring packs broke. (Tough day working in the hay field)

With that said, time came to repair the rust. The usual places, so I thought I would put the project here so if anyone needs ideas:

http://s1143.photobucket.com/albums/n635/Ramcharger422in3/?albumview=slideshow

RamChargerCentral

  • Advertisement
  • ***

    Offline DRoCk

    • RCC Rookie
    • **
    • Posts: 423
    • Gender: Male
      • Hogjaw
    Re: Daily Driver rust repair
    « Reply #1 on: February 26, 2011, 10:06:13 am »
    Nice job!  Lots of good pictures of the process, should be helpful to me when I start in on my rust.  I'm really hoping that my inner panels are in better shape than yours were, although they are probably easier to fab than the outer panels.

    How did the replacement front lower 1/4 panels fit?  I've held off ordering any since I haven't decided what to do with the lower rear 1/4 area (I may bob it up above my rusty spots to match my cut front fenders).  I have used the replacement wheel arch pieces and wasn't totally impressed with the fit.
    1984 Ramcharger Royal SE Prospector

    Check out Hogjaw on Youtube...good 'ol fashioned southern rock!

    Offline Boons

    • Canuckistani
    • Full Member
    • ****
    • Posts: 2240
    • Gender: Male
    • Putting the "ass" in "Class"
    Re: Daily Driver rust repair
    « Reply #2 on: February 26, 2011, 03:32:05 pm »
    Very nice  {cool}
    1993 Dodge W-250 "Ronnie"
    CTD/Getrag 360/205/60 Detroit/AAM 10.5 Detroit/40" Trail grapplers

    Makin sparks and breakin parts.

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #3 on: February 26, 2011, 07:25:22 pm »
    Guys,Thanks
    I have repaired rust in these Dodges since my first truck, 1961 Power Wagon, and have found every one rusts the same way until they changed cabs in 1994. The lower portion of the truck basically disolves. What I found is that folks seem to mistake wore hinges for what is really collapsed cab supports, and in my case here, a B pillar that also has a whole lot of rust damage. This creates a misalignment in the door. So when a door that wont close appears to have play in the hinge, but the person checking is actually picking the cab up off the collapsed cab support, and the dor aligns enough to close. The real cause is the collapsed support and B pillar that is not supported.

    So I got the repair panels from Mill Supply. They were super easy to deal with and actually speak to someone in english who was from the USofA.

    So here is the deal with the panels:
    - the front fender repair of the lower rear portion fit well. The area above the wheel opening just needed to have rust cut out and a small patch fit from flat sheet metal.
    - the front of the rear quarter panel repair fit well also.
    - the quarter panel repair behind the wheel opening required me to weld an extension on the panel mainly because the amount of rust damage was more than what the panel would cover.
    - the front cab support was really for a 74-80 early Ramcharger, but fit super well and was I think better than the orignal cab support.
    - I could not find for the life of me anyone that had a rear cab support, so Just bend one up using  a couple pieces of 2x4 wood into a vise and bend some flat sheet metal using your thumbs.
    It is cheap and works well.

    All the inner panels like the inner rocker and inner quarter are flat sheet metal and easy to make a  paper template and cut from a sheet steel...

    It is best not to lap joint the welds, but if you do, be sure to seal the seams so water does not collect and rot it out again. Stitch welding works well. The panel does not get hot and it is easy to grind smooth.

    The place that may be a challenge is the front lower portion of the inner rear wheel well house. But for that just take your time and start with a construton paper template so you have an idea of what the initial shape need to be and bend it accordingly.

    I guess dont be overcome with the amount of rust. Just break in down into small projects . Time wise, mine took 72 hours to complete.

    Offline Badart

    • Newbie
    • *
    • Posts: 213
    • Gender: Male
    Re: Daily Driver rust repair
    « Reply #4 on: February 26, 2011, 10:00:21 pm »
      I will never complain about rust again.   :o  Nice write up and thanks for sharing.
    1971 Dodge Dart<br />1966 Plyouth Fury III 440<br />1974 Dodge W100 Utiline

    Offline BIGTRUCKNUT

    • Jr. Member
    • ***
    • Posts: 969
    • Gender: Male
    • Common sense is an uncommon virtue.
    Re: Daily Driver rust repair
    « Reply #5 on: February 27, 2011, 05:33:20 am »
    Wow, lots of work.  That NJ road salt just eats stuff up!  My RC isn't quite that bad but I'm going a different route with a swap over to a P/U cab and tube bed. 

    You mentioned hay fields, where are you in NJ?  I grow up in Sussex County, bailed a lot of hay growing up.  Bought my '88 RC new off the lot in Newton after graduating college.  Looking forward to seeing your finished project.

    Ty
    Ty Yanvary USMC (ret)

    88 RC, 360/NP435/205, Dana 60s w/crossover and high-steer, rear shackle flip, 37s, '45 GPW, '63 M43, '73 CJ5, '04 Excursion PSD, '00 "SuperDuty" WJ, CJ8

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #6 on: February 27, 2011, 09:53:06 am »
    Ty,
    Thanks. Since I lost my job in 2007, I have been farming hay in Pittstown, Hunterdon County. Last year we had drought and year before it never stopped raining, so things are tough right now. Hay inventory is very low in my barn and across the country.

    I first bought an 88 RC new also, but sold it and bought the first of a long line of Ford diesel  1 ton trucks. I am the second owner of the RC in the pictures where I repaired the rust. I also have an 1980 TD that is a rust free rolling shell. That truck is a father son project with my 16 year old. The TD has a 422 inch W2 head small block for power. I have an np435/241 for that truck and look forward to cruzin the beaches in it. The TD is a work in progress, but I am working to get my daily driver, 88 RC, finished first.

    I also have a 498 inch big block that will one day find a home in a RC or TD.

    I see USMC by your name. Thank you Sir for your commitment to this country.

    My Dad was at Pearl Harbor and saw his friends go down with the Arizona. I forgot the name of his ship, but I understand it was the only one that escaped Pearl during the attack.

    My friend JT, just got his new leg and is up and walking again. He was PathFinder in Vietnam. You guys keep us safe .
    Jeff

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #7 on: March 5, 2011, 08:21:23 pm »
    Depending on the degree of rust you have to deal with, there are two sources for sheetmetal I found:

    http://www.rustrepair.com/index-mf.html
    http://www.autobodyspecialt.com/

    Mill Supply (rustrepair.com) has cab supports and some harder to find patch panel
    autobodyspecialt.com has larger panels if your rear quarters are rusted up to the bed rail.....

    Offline deans93

    • Newbie
    • *
    • Posts: 116
    • Gender: Male
      • deansdetail
    Re: Daily Driver rust repair
    « Reply #8 on: March 5, 2011, 08:40:12 pm »
    nice work, once i fix my brake leak then i'm back to my body work, thanks for the tip on sagging door, i check that next. I'm also going to add Rhino linings to mine, but also adding fender flares. making my own panels so i know it's going to take alot longer than 72 hours (more like 72 days)

    Offline rb89318

    • Jr. Member
    • ***
    • Posts: 519
    Re: Daily Driver rust repair
    « Reply #9 on: March 6, 2011, 05:39:44 am »
    Nice. Gives me the courage to try to fix mine. Only minor bottom rust. Mine is mostly the drip rail and some spots around the rear side windows.  Mine is mostly flat areas so I should be able to match paper templates. What guage sheet metal do you recommend?
    Formerly rb70383
    89 Ramcharger 5.2/auto
    85 D350 Crew

    Offline Billy Ram

    • Mopar Nut
    • ******
    • Posts: 5298
    • Gender: Male
    • RCC Rules!
    Re: Daily Driver rust repair
    « Reply #10 on: March 6, 2011, 11:06:43 am »
    Nice work. Gives me hope!!
    1999 Dodge Dakota Sport Extended Cab. 3.9 Magnum, 4 speed auto, 3:92 gears, Sure Grip diff.

    Offline redram80

    • Full Member
    • ****
    • Posts: 2010
    • Gender: Male
    • RCC kickin ass and takin names
    Re: Daily Driver rust repair
    « Reply #11 on: March 6, 2011, 01:21:52 pm »
    thanks for the pics ... i will be starting this as soon as the weather changes
    81 ramcharger 318 , 727 , 208 , dana44,9.25,hei ,31 mickey mtz,b&m truck shifter

    Offline big tracy

    • Newbie
    • *
    • Posts: 48
    • Gender: Male
    Re: Daily Driver rust repair
    « Reply #12 on: March 8, 2011, 10:20:26 pm »
    you interested in coming out to Minnesota and fix the rust on my RC?  ;D

    btw, way to go to keep another MOPAR on the road
    great work.
    More power More love

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #13 on: March 9, 2011, 11:20:48 am »
    Hey there rb89318 -
    If you are around the window, (presumably replacing window channel?) a shrinker/stretcher would help a lot. Lighter gauge steel would be easier to form, so I think 20 gauge would work well. If you are getting into repairing areas that have structural significance, (Like a rear cab support that I can't find premade anywhere) 18 gauge would work well. Some of the channel support like in the bed area, I would be using a 16 gauge.

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #14 on: March 9, 2011, 11:29:32 am »
    deans93 -
    I have to say that the replacement panels that generally rust on the RC's are really cheap and fit reasonably well. It is way easier and quicker to buy what you can and fab up the rest.

    If I remember right, I think I spent less than 200 for all the replacement steel in my RC. That was basically rebuilding the right and left inner and outter bottom of the truck. I promise you that if you are into fab'ing up panels, there is plenty of opportunity since most of the inner panels are not available.

    And if your B pillar or rear inner wheel house looks like mine, Enjoy bending and cutting!! ;D

    Offline rb89318

    • Jr. Member
    • ***
    • Posts: 519
    Re: Daily Driver rust repair
    « Reply #15 on: April 4, 2011, 01:07:56 am »
    Hey there rb89318 -
    If you are around the window, (presumably replacing window channel?) a shrinker/stretcher would help a lot. Lighter gauge steel would be easier to form, so I think 20 gauge would work well. If you are getting into repairing areas that have structural significance, (Like a rear cab support that I can't find premade anywhere) 18 gauge would work well. Some of the channel support like in the bed area, I would be using a 16 gauge.

    Thanks for the info. Bubbling rust around the side windows. ('89) and a hole through the rain channel above the windshield
    Formerly rb70383
    89 Ramcharger 5.2/auto
    85 D350 Crew

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #16 on: April 4, 2011, 02:42:02 pm »
    Hey rb89318,
    Around the rear window where is it bubbling should not be a problem if you catch it early. If it is under the trim and needs welding, definately remove the glass. If your are not comfortable with glass removal, get a glass guy. Thats what I did to remove the windshield and put a new window seal in. I can't deal with glass myself. I'm good with metal but suck with glass

    As far as the drip rail goes, if it is really just the drip rail itself then that is pretty straight forward to cut and weld in a new section. However, if the rust repair gets into the roof, then it is still not a big deal, but check out the Drip Rail repair at https://ramchargercentral.com/fabricationboard/drip-rail-fab/
    so you know what to expect.
    Jeff

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #17 on: May 9, 2011, 09:26:03 am »
    I had made some updates to the slide show in photo on my daily driver rust repair. With the weather good now, I'm going to paint the rest of the truck. But I did want to document how taking a project that looks pretty bad, really isn't if you break down into small manageable parts

    Offline Billy Ram

    • Mopar Nut
    • ******
    • Posts: 5298
    • Gender: Male
    • RCC Rules!
    Re: Daily Driver rust repair
    « Reply #18 on: May 9, 2011, 12:32:02 pm »
    Nice work, you make it look easy!!
    1999 Dodge Dakota Sport Extended Cab. 3.9 Magnum, 4 speed auto, 3:92 gears, Sure Grip diff.

    88mopar318

    • Guest
    Re: Daily Driver rust repair
    « Reply #19 on: May 9, 2011, 03:42:29 pm »
    Hell yea dude, looks nice! Good job!

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #20 on: May 15, 2011, 02:18:50 pm »
    Thank you. If you take your time, it really is not that hard to do a decent job repairing rust on these trucks.
    What Im afraid of is that over time, more and more RC's and TD's get parted out and what remains then crushed and scrape steel shipped overseas and come back as something from China.

    Over time this obviously reduces the pool of good (especially early) RC's & TD's trucks out there for us to buy, sell, trade. How many '74 RC's or TD's have you seen that have the window track built into the roof and are typical looking hard top convertibles? Not many left....

    Anyway, This is why I tried to have a photo document that illustrates that even when the cab supports, rockers and B-pillars are rotted out and causes the doors not to close, that truck can be made solid again.
    Jeff

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #21 on: August 20, 2011, 01:33:51 pm »
    Just wanted to show the final result of properly doing rust repair. The area on the bottom of my RC has been replaced, sealed and rhinolined so it will not rust out again.

    Offline Elwenil

    • Mopar Parts Manager
    • Global Moderator
    • RCC Addict
    • *****
    • Posts: 30066
    • Gender: Male
    • Better to be a Wolf of Odin than a lamb of god.
    Re: Daily Driver rust repair
    « Reply #22 on: August 20, 2011, 01:42:19 pm »
    Nice looking truck.  I normally don't like brown but a nice metallic "root beer" color has always caught my attention.  Love the gloss in that paint, looks great!
    L.Clemons

    1988 Ramcharger AW450-318EFI-NP435 4 speed-NP205 Transfer Case-Dana 60s-Braden Wormdrive Front Winch

    2018 Ram 2500HD Crew Cab 4WD 5.7L

    I am the unknown Will,
    The Anger that threatens glory and ruin:
    Lord of Storms am I,
    in heaven high and caverns deep.
    I am the Father of the War,
    Odin for you, Wotan for him,
    Wayfarer, Wanderer, beggar, king,
    numen, genius, strength and ring.

    Offline rb89318

    • Jr. Member
    • ***
    • Posts: 519
    Re: Daily Driver rust repair
    « Reply #23 on: August 21, 2011, 01:19:50 am »
    Nice looking RC. Awesome color too.  ;D My CTD is brown and tan interior. Same as my first car. It is a lighter shade though. What color is that? Looks really good on the RC. I am still waiting on getting into mine. Fixing other issues/vehicles first. LOL
    Formerly rb70383
    89 Ramcharger 5.2/auto
    85 D350 Crew

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #24 on: August 21, 2011, 07:43:06 am »
    The color is PPG Dark Suede Polly PK9 with Deltron DC4000 clear shot over it. I used the Deltron clear because it is currently the best available on the market and has UV protection built into it.

    If you have gone this far, dont skimp on the quality of the paint products.

    Lanty, The 241 I bought from you is going to go in this truck.
    Jeff

    Offline Billy Ram

    • Mopar Nut
    • ******
    • Posts: 5298
    • Gender: Male
    • RCC Rules!
    Re: Daily Driver rust repair
    « Reply #25 on: August 21, 2011, 10:16:49 am »
    Truck came out great. Nice job!!!
    1999 Dodge Dakota Sport Extended Cab. 3.9 Magnum, 4 speed auto, 3:92 gears, Sure Grip diff.

    Offline Elwenil

    • Mopar Parts Manager
    • Global Moderator
    • RCC Addict
    • *****
    • Posts: 30066
    • Gender: Male
    • Better to be a Wolf of Odin than a lamb of god.
    Re: Daily Driver rust repair
    « Reply #26 on: August 21, 2011, 01:02:02 pm »
    Jeff, it looks great.  Good to see my old transfer case will go to a good home.
    L.Clemons

    1988 Ramcharger AW450-318EFI-NP435 4 speed-NP205 Transfer Case-Dana 60s-Braden Wormdrive Front Winch

    2018 Ram 2500HD Crew Cab 4WD 5.7L

    I am the unknown Will,
    The Anger that threatens glory and ruin:
    Lord of Storms am I,
    in heaven high and caverns deep.
    I am the Father of the War,
    Odin for you, Wotan for him,
    Wayfarer, Wanderer, beggar, king,
    numen, genius, strength and ring.

    Offline rb89318

    • Jr. Member
    • ***
    • Posts: 519
    Re: Daily Driver rust repair
    « Reply #27 on: August 22, 2011, 12:50:22 am »
    Thanks for the info. Dont worry I will be referring to your posts when I start mine. Gonna start on the inside though fixing my inner wheel wheel and patching a gas tank access hole that got cut into my floor. ::)
    Formerly rb70383
    89 Ramcharger 5.2/auto
    85 D350 Crew

    Offline dwc2134

    • Newbie
    • *
    • Posts: 98
    • Gender: Male
    Re: Daily Driver rust repair
    « Reply #28 on: August 25, 2011, 12:41:48 am »
    Great info and pics, my soon to be new to me r/c's got similar rust on the rockers, though nowhere near as deep. Gives me hope that as soon as I learn to weld it shouldn't be too awful much of an issue to get it all repaired.
    '88 Dodge Ramcharger, 318 TBI, 727, 4WD
    4" RC all spring lift, 33x12.50 MTRs

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #29 on: April 22, 2012, 07:34:59 pm »
    Giving this a bump.... I saw some questions on rust repair that I believe this could be a help for some members. ;)

    BTW - after 358K miles the stock 318 gave up the ghost..... I'm probably going be putting a 360 in as soon as I heal up.

    Offline ramcharger422in3

    • Lifetime Supporter
    • RCC Rookie
    • *
    • Posts: 318
    • Gender: Male
    • If you didn't build it, it's not yours
    Re: Daily Driver rust repair
    « Reply #30 on: March 7, 2018, 12:36:03 pm »
    After years of wheelin this truck, I slid into a tree and bent the body. RIP.....  :-[ Now Im working on a '78 TD with a rust free tub. I hope to get it going this year.