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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. |
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The original box sides are spot welded to
the seam of the box rail. |
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The seam is sealed on both sides with seam
sealer from factory. |
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However, over the years, the seam sealer has
dried and cracked. |
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The area is sandblasted, any visible rust
is removed. |
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New metal is fabricated and welded into place. |
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This was a bit of a trick that required a
some creative metal bumping. |
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The metal is formed until it fits perfectly. |
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Then it's welded in place. |
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Outer
Panel Prep - Passenger Side |
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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. |
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Cut out the paper along the lines and you'll
have a perfect sized template to fabricate a repair piece. |
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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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