Rust repair- Cab and frame resto - Ford Powerstroke Diesel Forum
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Old 02-08-2014, 08:47 AM
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Rust repair- Cab and frame resto

Been working on a truck at work for about the past month... early '99 cab and chassis truck, with about 218K miles. Got new injectors about a year ago, so the extent of the repairs was deemed reasonable... will start with this picture of my truck jump starting it a few months ago... and add to it as time permits.

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Old 02-08-2014, 01:44 PM
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Started by clearing out the garage and pulling off the bed... about all the tractor (Kubota L4310 HST for thoes who wanna know) wanted to lift... 13' long.



Cab corners and inner/outter rocker panels were obviously going to need replaced on the driver side. Little did we know...





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Old 02-08-2014, 01:52 PM
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Started drilling spot welds... next thing I knew I was stripping the inside of the cab and took off the door.







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Old 02-08-2014, 02:07 PM
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Replacement sheet metal was purchased... if available. Cab corner, inner and outter rocker panel... no problem. But we needed floor pan parts and floor support braces as well.



The inner rocker doesn't go to the front of the cab. Lucky for me it's flat sheet but I had to cut out part of the cab mount to remove the damaged area. This is below the floor pictured above, below the door hinges/front piller.



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Old 02-08-2014, 02:33 PM
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Started forming some replacement parts. Using the ox/act torch to heat where needed and bending as needed... some dolly blocks and body hammers (thanks uncle Ed, RIP) and here ya have it.







Not all one piece to start with... but cut and bent to fit then MIG welded together, then a buncha grinding to smooth out seams.





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Old 02-08-2014, 02:45 PM
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That brings me to the next step... rear cab mount/floor support. Can you see where this is going?



Cutting out the floor made access much easier.



What I cut out and the in-progress replacement.



Finished... trimmed up and smoothed before install. This is the only part welded in at this point, everything else is held with screws untill we're sure what coatings will be used in what places... more on that later.



We now shifted gears... the frame and cross members need some attention.


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Old 02-08-2014, 03:39 PM
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The weather turned bitter cold which ment not using the exhaust fan as much so I spent time doing disassembly of the rear of the truck. Crossmembers were rotted and frame rails questionable. This is the rear-most crossmember that the fuel tank hangs from.



Everything from the cab back was removed. Even rivits... almost 100 of them!



The amount if missing metal is obvious by the contour. The full thickness remains at the rivit areas. This is the left side spring hanger area.



Lose scale rust was removed by beating the frame with a hammer, a welders chipping hammer, and mostly an air chistle. When cleaned up, the removed scale filled a 5 gallon bucket.


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Old 02-08-2014, 04:22 PM
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After about 2 full days of chipping rust, grinding and wire wheel work I was satisfied the frame rails were as clean as they were gonna get. Phone calls to dealers and body shops yielded no replacement cross members. Time to start some fab work... this is the start of all 4 needed.









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Old 02-08-2014, 04:47 PM
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After the top part of the front 2 cross members were done it was on to the side braces. The curve/angles was needed for exhaust clearance.









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Old 02-08-2014, 05:00 PM
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Last to fab up was the drive shaft support bearing bracket that goes under the front cross member.




All four complete...



End of the day friday... coated the frame rails with a rubberized rust encapsulater from Eastwood.



Untill now I have been posting in the fabrication forum in the welding projects thread. Check it out as there are a few other pictures and details I'm sure I've missed here. Pages 5-7.

http://www.powerstroke.org/forum/sho....php?p=8161298

As things progress I will update things here. The reassembly of the rear, the additional cab floor/supports, and when this is done... the other truck comes in. Also in the fleet to be repaired is a 2000 ext cab that will be getting simular cab repairs. Stay tuned!


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Last edited by dieselcrawler; 02-09-2014 at 07:07 AM.
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