how to patch these rust spots

R

richrd

New Member
my 2013 ford f150 is in excellent shape except for rust at the two rear corners of the cab. If I decide to try to fix this myself (painting is no problem), how would I go about it? I have "moderate" welding skills.
thanks
Rich
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Start by researching if patch panel sections are available for your truck. Yours rusted so it's likely a lot of others rotted in the same spot.
 
For best results remove bed. It can be done with the bed on, but even with a 18" belt sander and care, it will be very hard to smooth it out. These panels can be glued, but a tube of the correct glue is $60 +. I cut out the rusty metal just above the blistered area, then look at the inside of the chunk I cut out. If the inner rust meets my cut off line, then I cut a little higher until there is no rust still inside. If there is foam inside, you will need to get that out as it will continue to hold moisture, as well as catch on fire if you weld it. It is a small area to try to overlap the metal without leaving a noticeable bump to smooth out, so butt welding at least that outer part will be the way to go. After it is painted, be sure to coat the inside with cavity wax. It comes in aerosol cans and a 360* spray wand.
 

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Your best bet is to take the bed off. Odds are you will have to gring the head of the bed bolts off, then replace them with new bolts and u nuts from the dealer. The aftermarket kits sold for the bolts and u nuts are a waste of money.

Also check to see how far the rust is in the door jamb. The replacements don't go in the jamb very far at all, maybe a 1/2" or so.

Like RenewAP said, make sure you cut far enough to get to clean metal to weld to.

Also check the rocker panels as well. Usually if the cab corner has a hole the rocker panels aren't far behind.
 
I take it the factory cab corners didn't have a weep hole?....... If that's the case, can a weep hole be added to the replacement cab corner patch?

Would a weep hole help prevent future rust issues?
 
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I was able to do mine on a Chev truck without removing the box. Rust was only at the bottom so I didn’t have to cut much out. I was able to reach from underneath and the side to get the mig in there. Grinding I added a 10” wheel to my die grinder so it could reach in. Be careful and go slow with that big of wheel. Turned out ok as I’m a newbie to this kinda work. I also did the rockers since I was painting anyway
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MJM said:
I take it the factory cab corners didn't have a weep hole?....... If that's the case, can a weep hole be added to the replacement cab corner patch?

Would a weep hole help prevent future rust issues?
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There are all kinds of drain holes and channels when they leave the show room, but the first bit of sand, leaves and mouse nests plug them up, so from that point on it is a damp spot for rust to start. Hosing everything out every 2-3 months can keep them open longer, but it will start rusting eventually. Plus most models come with foam or spongy adhesives inside that also hold moisture. Add salt or road brine to it and most new vehicles up here in Wisconsin are showing rust around year 6. I have a heavy demand for 2015+ suburban rockers panels, even had one customer asking about the 2018+ Expedition panels already. 2015 Silverado pictured
 

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If i paid 40-60k for a brand new pick up truck, and it looked like that after 10 years or less, id be pissed!!..Do the Tundras rust like that?..
 
hapcj7 said:
If i paid 40-60k for a brand new pick up truck, and it looked like that after 10 years or less, id be pissed!!..Do the Tundras rust like that?..
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Everything that gets driven up here rusts like that. That's why I got into the replacement panel & paint supply business. If you see a older vehicle up north with no rust, then it just came up from the south, or just got new panels installed.
 
RenewAP said:
Everything that gets driven up here rusts like that. That's why I got into the replacement panel & paint supply business. If you see a older vehicle up north with no rust, then it just came up from the south, or just got new panels installed.
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I'm just trying to keep you in business Randy!!
 
A big part of it is in the winter people park in heated garages. Salt and snow melt along with the mud that gets packed in and it never dries.
 
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