Warning, I like to write and these posts will be long as an encyclopedia
A few of you know, I am doing major rust repair on the rig. I am not a body guy, not certified, nothing. I am in my last year of high school and thought I'd try some free college through dual enrolling. Where you drop 1 or 2 classes from HS and take a college course, but only if it's a course not offered at the high school, you recieve credit at HS for the courses based on the contact hours, and obviously receive college credit.
I'm attending Mott Community College - Southern Lakes Branch Campus in Fenton MI, on Tuesday and Thursday nights from 6-10 pm. Not a bad deal since I dropped my first two classes at HS and go in at 9:35 instead of 7:25.
Oh and did I mention this college education is free? The tuition and any materials are paid for by the state because it is sort of considered high school education
I'm not sure how it works but it does.
Anyway, the first class was "Autobody - Welding & Metal Refinishing" where we learned how to MIG weld and weld different joints, resistance (pinch) weld, all on sheet metal. Also some metal shaping and dent repair using methods such as using a Panel Beater, and slide-hammer/stud method, ect ect. Also we learned how to REALLY use "Bondo"/Body filler, how to use it, mix it, and sand it. And also why it fails. (Not waterproof! And will not fix rust.) And the next semester was Autobody - Painting where we learn all the chemistry of automotive paints (hurts the brain) and how to paint using real spray guns, painting technique, different sanding methods and technique, and masking, most everything besides pinstriping and Tri-Coat (Candy colors and metal flake). Pretty cool.
At the end of each semester for the last couple months we're to bring in a project to work on. And here's why I chose to fix the SuperDuty... I've taken MANY MANY pictures because I'm not a fan of the work at all, and couldn't do it for a career, this is kind of a once in a lifetime experience for me. It's coming to a close, we have 3 lab days left so I thought it was time to make a big ole thread and post my work.
Thanks for reading!
Here we go. I'll try to put a decent caption explaining what each pic is. And I'll do my best to keep them in order.
Brought the truck in.
Took the whole headliner out, A-pillar covers, sun visors, seat belts, trim pieces, overhead light, weather-stripping all of it.
There was just a small spot of rust, that turned out to be completely through. Stabbed and pryed all that with just a screwdriver in about two minutes.
Obviously cutting that crap out.
Repair area cut out.
Repair area with paint ground off.
Close-up of the surface-rusted structural part.
That's how it was stored there.
Hand forming a patch piece.
Welding blanket protection.
Me welding patch in, all tack welds.
'nother of me welding. A neat pic I think.
Beginning of tack welds (this part took FOREVER)
More tack welds.
More tack welds..
More tack welds...
Cutting to fit body-line.
Replacing factory pinch welds. That's the instructor doing it. I had a pic of me standing next to that welder, it's taller than I am with the bar on top that holds the gun. It was funny.
'nother of pinch welds.
Starting body filler, first used Fiberglass reinforced filler, then regular filler. 5 coats total.
More body filler.
More body filler.
More body filler.
Last coat of filler for that area, before sanded.
Showing the roof contour. All hand sanding, only used a DA (Dual Action) sander once...
End of that semester, truck had to come home so there is a few coats of rattle can primer.
And black rattle can paint
Not bad for temporary finish?
That's how the truck was at the end of the first semester, the second semester (paint) has started and is almost over as I said before. I'll update in a while with pics of how the rest of the work is coming.