IMG_7850.JPG
708 hits | 67.67 KB | Posted: 12/25/12
Fenders trimmed to clear 37 inch swampers. need to do something to create a lip on the inner part of...

IMG_7851.JPG
543 hits | 52.96 KB | Posted: 12/25/12
Fenders trimmed to clear the 37 inch swampers

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473 hits | 41.5 KB | Posted: 12/25/12
Another shot of trimmed drivers side rear fender.

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480 hits | 49.18 KB | Posted: 12/25/12

IMG_7848.JPG
460 hits | 49.47 KB | Posted: 12/25/12
crumpled drivers side fender.

IMG_7849.JPG
491 hits | 43.84 KB | Posted: 12/25/12
close up of the crunched drivers side fender.

20131125_100734[1].jpg
453 hits | 52.92 KB | Posted: 12/9/13
shiny new (to me) fender from a Bronco and matching color..this was before it got trimmed.

20131208_112246[1].jpg
410 hits | 57.15 KB | Posted: 12/9/13
Old fender about to come off.

20131208_121444[1].jpg
417 hits | 62.84 KB | Posted: 12/9/13
accidentally cut into the tub while removing the old fender so I welded it up..

20131208_124110[1].jpg
444 hits | 60.48 KB | Posted: 12/9/13
not the greatest job but it's not something anyone is going to see so it will do..I hit it with some...

20131208_112254[1].jpg
439 hits | 43.44 KB | Posted: 12/9/13
you can see the alignment pins for the fender behind the headlamp bezel.

20131208_114959[1].jpg
515 hits | 67.34 KB | Posted: 12/9/13

20131208_114950[1].jpg
468 hits | 82.62 KB | Posted: 12/9/13
Drivers side fender completely removed. In the lower right hand corner you can see the rubber duck b...

20131210_074655[1].jpg
440 hits | 52.94 KB | Posted: 12/10/13
post trim, the new fender is just sitting there..looks much better.

bolted up fender.jpg
403 hits | 51.39 KB | Posted: 1/6/14
getting everything bolted up.

20131216_131355[1].jpg
393 hits | 59.1 KB | Posted: 12/16/13
here it is with the lower mounting bolt in .you can tell something got tweaked when I bottomed out b...

20131216_131404.jpg
413 hits | 74.41 KB | Posted: 12/16/13
side shot of how much it's bowed.

lower mounting bolt fender.jpg
371 hits | 37.39 KB | Posted: 1/6/14
lower mounting bolt that was giving me trouble..had to come back a grind off part of the tab so it ...

20131217_074855[1].jpg
392 hits | 34.24 KB | Posted: 12/17/13
used a pop rivet to connect the inner plastic fender to the outer. the result is much better than th...

20131115_100908.jpg
413 hits | 81.71 KB | Posted: 11/15/13
Tailgate lip started to rust. I had this repaired once by a shop that replaced the outer skin. They ...

20131115_100913.jpg
449 hits | 90.74 KB | Posted: 11/15/13
another shot of the rust on the tailgate lip.

20131116_141805[1].jpg
442 hits | 59.32 KB | Posted: 11/18/13
this is my attempt at a weld repair on the tailgate reinforcement this piece had completely cracked....

20131115_100926.jpg
455 hits | 71.98 KB | Posted: 11/15/13
more rust

20131118_192711[1].jpg
404 hits | 77.23 KB | Posted: 1/3/14
here are some of the products I used to fix the tailgate. Was able to get the oxford white duplicolo...

20131115_103714.jpg
403 hits | 60.36 KB | Posted: 11/15/13
this was outer skin with the fascia removed..that entire strip where the added the new skin was rust...

20131116_115320[1].jpg
400 hits | 63.5 KB | Posted: 11/18/13
the lip was the worst..I had to do a ton of grinding to clean it up with a wire cup brush, then hit ...

20131116_150629[1].jpg
462 hits | 41.61 KB | Posted: 11/18/13
outer tailgate skin sanded and hit with rust inhibitor

20131116_150650[1].jpg
370 hits | 48.64 KB | Posted: 11/18/13

20131117_132340[1].jpg
416 hits | 80.6 KB | Posted: 11/18/13
shot of the lip of the tailgate. this took a lot of sanding to get it even.

20131117_132424[1].jpg
395 hits | 47.75 KB | Posted: 11/18/13

20131117_132436[1].jpg
411 hits | 57.22 KB | Posted: 11/18/13

20131117_144731[1].jpg
394 hits | 69.52 KB | Posted: 11/18/13
Tailgate sanded and primed. not the greatest job, but at least there isn't any rust.

20131117_145524[1].jpg
417 hits | 50.34 KB | Posted: 11/18/13

IMG_6734.JPG
717 hits | 37.52 KB | Posted: 6/28/12
b-pillar passenger side right by the door jamb. You can see where the water coming in from the crack...

IMG_6731.JPG
707 hits | 18.4 KB | Posted: 6/28/12
b-pillar seam..you can see rust forming in the crack

IMG_6732.JPG
742 hits | 25.05 KB | Posted: 6/28/12
PS - underneath the rain gutter. this is obviously rusted through.

IMG_6733.JPG
664 hits | 26.88 KB | Posted: 6/28/12
back of passenger side rain gutter, rust is the worst here.

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683 hits | 38.05 KB | Posted: 7/2/12
passenger side rain gutter and cracks. you can clearly see the rust bubbling up underneath the paint...

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969 hits | 55.76 KB | Posted: 7/2/12
passenger side access panel. this was from a previous attempt at repairing the cracks.

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698 hits | 46.37 KB | Posted: 7/2/12
Inside the access panel, looking at the back side of the rain gutter, passenger side.. You can see w...

IMG_6965.JPG
737 hits | 41.45 KB | Posted: 7/2/12
another shot inside the passenger side sail panel..once I get it cleaned up, I'll douse the inside w...

20131228_134250.jpg
549 hits | 50.71 KB | Posted: 12/29/13
inside of the passenger sail panel..look at all the rust..going to hit it with rust treatment.

In h...

20131228_134256.jpg
514 hits | 55.5 KB | Posted: 12/29/13
another shot of the sail panel inside towards the back

20131228_135422.jpg
488 hits | 55.32 KB | Posted: 12/29/13
passenger side drip rail..this side had about a 1/4 inch gap where it had rusted through at the top.

20131228_135434.jpg
605 hits | 61.29 KB | Posted: 12/29/13
a shot from the back of the passenger side drip rail before I started cleaning it up..

the grey stu...

20131228_140600.jpg
583 hits | 48.74 KB | Posted: 12/29/13
passenger side drip rail cleaned up..the rust was a lot worse than I thought. you can see the huge g...

20131228_140605.jpg
583 hits | 56.34 KB | Posted: 12/29/13
back of the drip rail..

shot inside sail panel.jpg
518 hits | 49.42 KB | Posted: 1/6/14
shot from the inside of the sail panel, I was able to easily knock out the old reinforcement panels...

20131228_140813.jpg
515 hits | 38.53 KB | Posted: 12/29/13
another shot from the inside of the sail panel with the reinforcement panel removed...the will need ...

20131228_140802.jpg
516 hits | 52.74 KB | Posted: 12/29/13
this is on of the factory TSB kit reinforcement panels..the rust is mostly surface so I may actually...

20131228_141012.jpg
546 hits | 41.94 KB | Posted: 12/29/13
both reinforcement panels

20131228_141114.jpg
516 hits | 48.8 KB | Posted: 12/29/13
the view with both panels removed..this was a lot worse than I thought.

20131228_142656.jpg
711 hits | 52.57 KB | Posted: 12/29/13
back of the sail panel, I ground out as much of the old seam sealer as I could..this was in pretty g...

20131228_142705.jpg
623 hits | 46.42 KB | Posted: 12/29/13
drip rail cleaned up with rust treatment applied..ready to repair..

20131230_143104.jpg
534 hits | 62.88 KB | Posted: 1/1/14

20131231_105953.jpg
482 hits | 53.53 KB | Posted: 1/1/14
test fitting my reinforcement panel.

20131231_110003.jpg
525 hits | 57.79 KB | Posted: 1/1/14
started welding up the corner where the cracks were.

20131231_125126.jpg
470 hits | 50.54 KB | Posted: 1/1/14
good thing I had this spare fender was able to use it to cut my new reinforcement panels and other p...

20131231_134702.jpg
486 hits | 62.38 KB | Posted: 1/1/14
welded and ground down. not the best job, but with the panels in place from the inside, it should be...

20131231_142311.jpg
479 hits | 30.96 KB | Posted: 1/1/14
passenger hole below the drip rail. It had rusted all the way through so I had to cut to clean metal...

repair primed 1.jpg
548 hits | 32.18 KB | Posted: 1/1/14

20131231_151541.jpg
541 hits | 81.48 KB | Posted: 1/1/14
This is permatex product called cold weld. it has a sheer strength of 3000 psi once it is fully cure...

20131231_151555.jpg
514 hits | 47.04 KB | Posted: 1/1/14
my homemade reinforcement panel. I'll be using this one on the passenger side. made from a piece of ...

start of rust repair b-pillar 2.jpg
564 hits | 43.82 KB | Posted: 1/6/14
huge hole from rust in the ps b-pillar

20131228_142647.jpg
512 hits | 42.26 KB | Posted: 12/29/13
here is where the sail panel meets the body, still need to do some cutting to clean it up.

rust removal b pillar.jpg
677 hits | 43.91 KB | Posted: 1/3/14
this area around the seam in the pillar was bad. going to need to do some cutting to get to clean me...

sail panel 1 pre cut.jpg
492 hits | 25.93 KB | Posted: 1/1/14

20131231_104557.jpg
508 hits | 39.3 KB | Posted: 1/1/14
cut out all the bad material and ready to start patching the sail panel from the inside.

repair primed 2.jpg
520 hits | 38.91 KB | Posted: 1/1/14
all of the rusted metal cut out from the b-pillar. In hind sight I probably should have cut a bigger...

sail panel cut primed.jpg
486 hits | 23.96 KB | Posted: 1/1/14
b-pillar primed over

20131231_155612.jpg
498 hits | 40.89 KB | Posted: 1/1/14
first patch in place.

panel reinforcement.jpg
484 hits | 45.17 KB | Posted: 1/3/14
Ignore this.

panel work.jpg
444 hits | 39.59 KB | Posted: 1/3/14
shot from the rear of the passenger side sail panel.

20140104_101131.jpg
459 hits | 33.93 KB | Posted: 1/4/14
one patch in the b-pillar. patch was cut out from the old fender 18 gauge and attached with the cold...

20140104_110438.jpg
540 hits | 33.94 KB | Posted: 1/4/14
second b-pillar patch in...

b pillar both patched.jpg
509 hits | 32.95 KB | Posted: 1/4/14
the permatex cold weld sets up much more quickly that JB weld, so you have to work fast..

20140105_111009.jpg
439 hits | 37.98 KB | Posted: 1/6/14

20140104_111759.jpg
533 hits | 49.93 KB | Posted: 1/4/14
test fitting my patch for the roof..Initially I was going to, but I decided to weld this in place. t...

20140104_134426.jpg
471 hits | 44.93 KB | Posted: 1/4/14
here are y booger welds...no it's not pretty..but the the hole is closed up..

20140104_150847.jpg
463 hits | 45.37 KB | Posted: 1/4/14
grinding down the welds..this took a while since I had to keep going back to re-welding spots I miss...

20140104_151049.jpg
472 hits | 41.61 KB | Posted: 1/4/14
getting closer.

20140105_110941[1].jpg
437 hits | 51.98 KB | Posted: 1/6/14
shot from the inside with both patches in place. at this point it is just the patch. I am going to a...

20140105_110944.jpg
502 hits | 50.09 KB | Posted: 1/6/14

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452 hits | 41.29 KB | Posted: 1/6/14

20140111_104729.jpg
430 hits | 57.91 KB | Posted: 1/11/14
this is about at good as it's going to get..need to put some primer on it so it doesn't start rustin...

20140111_113446.jpg
413 hits | 46.6 KB | Posted: 1/11/14
used seam sealer in the gutter, but didn't let it cure long enough. wound up having to remove most o...

20140111_113456.jpg
426 hits | 47.86 KB | Posted: 1/11/14

20140111_105452.jpg
423 hits | 38.89 KB | Posted: 1/11/14
getting the b-pillar ready for filler.

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421 hits | 54 KB | Posted: 1/11/14
had to touch up the seam again.

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391 hits | 62.43 KB | Posted: 1/11/14

20140111_113525.jpg
416 hits | 50.93 KB | Posted: 1/11/14
top reinforcement panel in place I put as much cold weld in there as possible.

20140111_113527.jpg
432 hits | 53.04 KB | Posted: 1/11/14

20140111_113534.jpg
435 hits | 54.69 KB | Posted: 1/11/14

20140112_132713.jpg
434 hits | 67.99 KB | Posted: 1/13/14
prepping the b-pillar..didn't work too well with my angle grinder, so I picked up a D/A sander from ...

20140112_132719.jpg
401 hits | 64.07 KB | Posted: 1/13/14

20140112_132725.jpg
380 hits | 55.79 KB | Posted: 1/13/14

20140112_132733.jpg
425 hits | 69.14 KB | Posted: 1/13/14
rain gutter, almost done..need some cold weld to fill in the drip rail a bit.

20140112_134013.jpg
439 hits | 60.52 KB | Posted: 1/13/14
another gift from the rust Gods. This was the front of the drip rail, luckily nothing had gone throu...

20140112_134021.jpg
385 hits | 66.4 KB | Posted: 1/13/14

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387 hits | 73.27 KB | Posted: 1/13/14

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424 hits | 59.97 KB | Posted: 1/13/14

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377 hits | 74.1 KB | Posted: 1/19/14
harbor freight specials. I think I spent about $60 for both..the D/A sander has been great..haven't ...

20140118_095745.jpg
381 hits | 56.86 KB | Posted: 1/19/14
Interior shot of the b-pillar...it doesn't look pretty but hopefully the rust won't come back any ti...

20140118_095750.jpg
421 hits | 56.39 KB | Posted: 1/19/14

20140118_135835.jpg
430 hits | 49.13 KB | Posted: 1/19/14
roughed up the b-pillar with the D/A sander and some 80 grit..seemed to work pretty well.

20140118_135839.jpg
423 hits | 51.97 KB | Posted: 1/19/14

20140118_143732.jpg
395 hits | 60.13 KB | Posted: 1/19/14
had to move the Bronco into the garage to paint. it was still a tight squeeze, even after losing 20l...

20140118_145047.jpg
405 hits | 64.01 KB | Posted: 1/19/14

20140118_152701.jpg
413 hits | 38.04 KB | Posted: 1/19/14
getting the body filler in the seam..not sure if this is going to crack again or what but it should ...

20140118_152703.jpg
412 hits | 39.63 KB | Posted: 1/19/14

20140118_152715.jpg
414 hits | 45.99 KB | Posted: 1/19/14
rain gutter almost done.

20140118_152747.jpg
377 hits | 43.09 KB | Posted: 1/19/14

20140118_155832.jpg
403 hits | 48.72 KB | Posted: 1/19/14
patched the lower hole, used pop rivets and cold weld..hopefully I didn't lose too much rigidity her...

20140118_155842.jpg
392 hits | 45.95 KB | Posted: 1/19/14
all primed up inside...hesitant to put the cover on, would still like to get some more rust inhibito...

20140118_155846.jpg
363 hits | 45.29 KB | Posted: 1/19/14

20140118_160904.jpg
391 hits | 39.87 KB | Posted: 1/19/14

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357 hits | 44.94 KB | Posted: 1/19/14

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395 hits | 48.74 KB | Posted: 1/19/14

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443 hits | 45.16 KB | Posted: 1/19/14

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419 hits | 59.65 KB | Posted: 1/19/14

20140118_165630.jpg
397 hits | 49.73 KB | Posted: 1/19/14
sail panel primed, ready to paint.

20140118_165649.jpg
367 hits | 49.42 KB | Posted: 1/19/14

20140126_131138.jpg
370 hits | 47.31 KB | Posted: 1/27/14
one final prime before painting. I used the self ething primer.

20140126_131156.jpg
381 hits | 53.54 KB | Posted: 1/27/14

20140126_150120.jpg
367 hits | 60.26 KB | Posted: 1/27/14
This was after a couple of coats of base. I used automotive touchup paint in an aerosol can. At $20 ...

20140126_150127.jpg
384 hits | 58.91 KB | Posted: 1/27/14

20140126_150135.jpg
360 hits | 57.05 KB | Posted: 1/27/14

20140126_150155.jpg
379 hits | 42.35 KB | Posted: 1/27/14
The rain gutter came out much better than I thought it would.

20140126_150206.jpg
401 hits | 54.66 KB | Posted: 1/27/14

20140126_152441.jpg
408 hits | 63.84 KB | Posted: 1/27/14
I'll get another shot with the tape and everything removed. all in all it turned out pretty good..At...

20140127_174730[1].jpg
433 hits | 39.7 KB | Posted: 1/28/14
you can see the difference between the two paints where it was taped off. Plan is to feather the new...

20140127_174747[2].jpg
481 hits | 34.71 KB | Posted: 1/28/14
rain gutter came out pretty good, you can see some waves, but it looks fine from 10 ft away...

20140202_130102.jpg
395 hits | 63.01 KB | Posted: 2/3/14
not happy with the uneven way the paint looked, I sanded to whole pillar again and re-primed to get ...

20140202_130109.jpg
389 hits | 63.1 KB | Posted: 2/3/14

20140202_132920.jpg
374 hits | 57.19 KB | Posted: 2/3/14
primer dried, ready for 1st coat of paint.

Repaint1.jpg
414 hits | 47.79 KB | Posted: 2/3/14

Repaint2.jpg
357 hits | 47.01 KB | Posted: 2/3/14
paint down, time for clear coat.

Repaint3.jpg
373 hits | 38.54 KB | Posted: 2/3/14
looks much better with the pain blended.

Repaint4.jpg
394 hits | 37.19 KB | Posted: 2/3/14

20140202_155334.jpg
432 hits | 33.06 KB | Posted: 2/3/14

20140202_155355.jpg
668 hits | 32.13 KB | Posted: 2/3/14
Rain gutter finished.

20140203_101600.jpg
403 hits | 58.17 KB | Posted: 2/3/14
passenger side done with the top back on..looks good.

20140203_101609.jpg
408 hits | 44.17 KB | Posted: 2/3/14

20140118_170148.jpg
421 hits | 34.65 KB | Posted: 1/19/14
This is the front of the driver's side rain gutter. Willing to bet that hole is all the way through....

20140118_170151.jpg
364 hits | 35.84 KB | Posted: 1/19/14

20140118_170212.jpg
350 hits | 32.38 KB | Posted: 1/19/14
drivers side sail. I don't think it's as bad as the other side, but the paint is going to have to co...

20140118_170221.jpg
354 hits | 27.66 KB | Posted: 1/19/14

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374 hits | 35.58 KB | Posted: 2/3/14

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412 hits | 44.01 KB | Posted: 2/3/14

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389 hits | 41.85 KB | Posted: 2/3/14

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397 hits | 50.57 KB | Posted: 2/3/14

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419 hits | 46.33 KB | Posted: 2/3/14
gap in the seam on the drivers side rain gutter. you can see how the seam has separated, and I'm pre...

seam crack drivers side.jpg
517 hits | 46.81 KB | Posted: 2/3/14

20140208_140019.jpg
373 hits | 45.06 KB | Posted: 2/8/14
about to open the drivers side..this one had rivets in it and one screw...can't wait to how the insi...

20140208_140333.jpg
362 hits | 42.12 KB | Posted: 2/8/14
not great, but not as bad as I thought..your can see the reinforcements panels are starting to rust....

20140208_140339.jpg
389 hits | 52.59 KB | Posted: 2/8/14
another view of the rust on the drivers side.

20140208_140348.jpg
355 hits | 47.64 KB | Posted: 2/8/14
at least the rust doesn't seem to be as wide spread as it was on the passenger side.

20140208_140357.jpg
377 hits | 44.49 KB | Posted: 2/8/14
picture down inside the b-pillar you can see the rust stain running towards the floor.

20140208_140401.jpg
397 hits | 40.06 KB | Posted: 2/8/14

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379 hits | 46.96 KB | Posted: 2/8/14

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393 hits | 56.84 KB | Posted: 2/8/14
fortunately, both of the reinforcement panels pulled right off..there goes the top..and I think I'll...

20140208_140922.jpg
415 hits | 55.89 KB | Posted: 2/8/14
this is what was behind the reinforcements. the rust was all on the surface. would have been nice i...

20140208_140928.jpg
392 hits | 50.5 KB | Posted: 2/8/14

20140208_140958.jpg
367 hits | 108.4 KB | Posted: 2/8/14
again, whoever did the repair before, did a piss poor prep job..

20140208_144217.jpg
412 hits | 52.25 KB | Posted: 2/8/14
cleaning up the inside..not sure if I'm going to have to weld up the corner yet or not. there are a ...

20140208_145903.jpg
392 hits | 33.95 KB | Posted: 2/8/14

20140208_145915.jpg
352 hits | 29.97 KB | Posted: 2/8/14
these gray blobs are the remnants of the holes from my old soft top bracket. will smooth them down t...

20140208_151324.jpg
387 hits | 32.2 KB | Posted: 2/8/14

20140208_152206.jpg
486 hits | 30.87 KB | Posted: 2/8/14
rear shot of the drivers side rain gutter, the previous shot that did this repair did a real crap jo...

20140209_135025.jpg
399 hits | 69.63 KB | Posted: 2/10/14
cleaning up the old filler.

20140209_135037.jpg
371 hits | 77.76 KB | Posted: 2/10/14

20140210_192845.jpg
341 hits | 58.28 KB | Posted: 2/11/14

20140210_192902.jpg
369 hits | 55.9 KB | Posted: 2/11/14
bought the napa seam sealer product. came in beige, not a big deal since I'll be painting it. Applie...

20140210_192912.jpg
380 hits | 41.88 KB | Posted: 2/11/14
underneath the rain gutter.

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434 hits | 52.37 KB | Posted: 2/11/14
front gap filled.

20140210_192935.jpg
364 hits | 49.71 KB | Posted: 2/11/14

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361 hits | 37.82 KB | Posted: 2/11/14
front of the rain gutter. this came out ok.

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396 hits | 71.39 KB | Posted: 2/17/14

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382 hits | 34.36 KB | Posted: 2/17/14

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337 hits | 38.47 KB | Posted: 2/17/14

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338 hits | 39.04 KB | Posted: 2/17/14

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351 hits | 50.81 KB | Posted: 2/17/14

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497 hits | 46.97 KB | Posted: 2/17/14
seam sealer in the drivers side rain gutter.

20140215_153124.jpg
594 hits | 68.71 KB | Posted: 2/17/14
shot of the drivers side b-pillar after it was primed.

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360 hits | 64.57 KB | Posted: 2/17/14

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382 hits | 47.79 KB | Posted: 2/17/14

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355 hits | 42.59 KB | Posted: 2/17/14

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354 hits | 43.58 KB | Posted: 2/17/14

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362 hits | 41.78 KB | Posted: 2/17/14

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333 hits | 62.54 KB | Posted: 2/17/14

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388 hits | 66.99 KB | Posted: 2/17/14

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375 hits | 66.9 KB | Posted: 2/17/14

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360 hits | 61.03 KB | Posted: 2/17/14

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336 hits | 50.79 KB | Posted: 2/17/14

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349 hits | 52.46 KB | Posted: 2/17/14

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360 hits | 47.88 KB | Posted: 2/17/14

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333 hits | 49.13 KB | Posted: 2/17/14

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383 hits | 53.78 KB | Posted: 2/17/14

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397 hits | 71.01 KB | Posted: 2/17/14

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356 hits | 59.4 KB | Posted: 2/17/14

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378 hits | 48.52 KB | Posted: 2/17/14

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371 hits | 48.6 KB | Posted: 2/17/14

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20140217_153118.jpg
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Bronco before and after passenger side.jpg
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side by side comparison of the passenger before and after the rust repair and body work.