<%@LANGUAGE="JAVASCRIPT" CODEPAGE="1252"%> 81tsb - Fabricate: Box Sides 6 - Outer Panel Prep, Driver Side
81 T sb

Replacement Box Sides

(6) Outer Panel Prep

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Outer Panel Prep - Driver Side

Theres only one way to repair rust, cut it out and replace it with new metal.

The original box sides are spot welded to the seam of the box rail.
The seam is sealed on both sides with seam sealer from factory.
However, over the years, the seam sealer has dried and cracked.
The area is sandblasted, any visible rust is removed.
New metal is fabricated and welded into place.
This was a bit of a trick that required a some creative metal bumping.
The metal is formed until it fits perfectly.
Then it's welded in place.
Outer Panel Prep - Passenger Side
Here is a tip: this type of metal fabrication involves creating a piece of metal that fits inside another piece of metal. Instead of using cardboard, use a piece of blank computer paper, place it over the hole, use your dirty fingers to press the paper onto the edges of the hole. By doing this, the dirt on your fingers will outline the hole onto the paper.
Cut out the paper along the lines and you'll have a perfect sized template to fabricate a repair piece.
Even the tiny rust pits are cut out and replaced with new metal.
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Again, place the blank computer paper over the hole, use your dirty fingers to press the paper against the edges of the hole. You can also use cardboard, but you'll be there forever cutting, trimming, checking, timming, checking etc.. etc...
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