Rust Repair in Bed


backporch

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I have a 99 extended cab that has spent its life in NJ and has its share of rust. As part of a repair to fix a bad fuel pump, I decided to pull the bed. When I pulled the plastic factory liner I saw some rust that I need to address. Looking for suggestions here as to how to approach restoring the bed.

The picture shows the worst of the rust by the mounting bolt just behind the cab on the fuel filler side. The other side is more solid. There is a lot of rust by the fuel filler.

I plan on trying to do a good structural repair and put back the factory liner. I like the look and usefulness of it. This truck probably only has a few good years left in it.
 


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adsm08

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What picture?
 

backporch

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The picture

OK... had to get picture small enough to be uploaded and it is still huge. The picture shows the bed right near the gas filler. The bed is rusted through. The "tube" that the bolt goes thorugh is still connected to the bed, but needs some obvious reinforcement. Looks like it may have been part of a angle support under the bed, but its hard to tell from what is left.
 

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Ranger850

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Price a better bed at the JY. Probably faster and easier than cutting out bad wavy pieces and replacing them with flat steel. Unless you love welding, of course.
 

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I agree. If the truck only has a a few years left either deal with it, or buy a new bed.
 

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Thanks for the suggestions

I think I may keep my eyes open for a better bed but it would have to be the same green color. A hang up of mine. In the meantime I am going to pull the bed and take a look underneath. My concern is that bolt tube that is barely holding on. It is like having a table with one wobbly leg

I think I may employ some angle iron rivets and fasteners to put back the strength that has been lost. I was also interested where to source bed panels but now it occurs to me that I just need to find a junk bed that I can cut some from. Most of my bed is perfect
 

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Most of your bed is perfect, except where it bolts to the frame. The floor of the bed gives it integrity. I'd rather have a solid bed than one that's matches. I wouldn't be hung up on a different color if your canning the truck in a few years. Plus it gives the truck character, a story of how its been on the road and is determined to stay on the road.
 

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Bed sides can be swapped. Find a good bed and put your side panels on it.
 

backporch

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Interesting. I have seen the step side bed sides are fiberglass and must be removable somehow. I don't have step side. Can those sides be removed? if so what does that involve? Fasteners or welding?

You guys are right on all points. I understand about the bed integrity and I do have plans to use the truck for weekend tasks, not just transporting lightweight items.
 

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On a fleet-side the bed sides are held on by a series of spot welds along the inner rail. You can cut them out and use bolts to reattach.
 

backporch

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That's interesting about the spot welds. A lot of work, but an option. There must be more all along the fender perimeter. I have seen them drilled with a special bit. is there a tool that makes quick work of separating the pieces of metal?

Any idea what beds fit a '99 and if the plastic fender flares can be removed and transferred to another bed?
 

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A drill and a flat head should be all you really need to separate the side panels. The beds are pretty much the same no matter what year as long as the body style is similar.
 
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adsm08

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That's interesting about the spot welds. A lot of work, but an option. There must be more all along the fender perimeter. I have seen them drilled with a special bit. is there a tool that makes quick work of separating the pieces of metal?

Any idea what beds fit a '99 and if the plastic fender flares can be removed and transferred to another bed?
https://www.ebay.com/itm/Spot-Weld-Cutter-Drill-Bit-5-16-6-pcs-made-in-USA/283297244574?hash=item41f5d4e59e:g:WosAAOSwWxNYpIkI:rk:7:pf:0

These will do the job quick. Using these it took me a little over an hour to disassemble a front clip, which is 23 spot welds.

My only regret with that one was buying only one, rather than the 6-pack. It started to dull a little over half way through and that slowed me down a good bit.

Also, be careful to not over-do it. There is a fine line between cutting the weld and punching a giant hole in your work piece. It wasn't a big deal for me because I was planning to put it all back together with bolts, but you should still be careful.
 

Ranger850

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you can ( if you have a welder ) spot weld it back on, if you use a metal side. If you go fiberglass, I would use epoxy and bolts.
 

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If the rest of the bed is fine other than the spot in the picture then I would get a piece of steel plate about 8"x8" or 10"x10" or get a plate that's 8"x8" with a right angle lip about 2-3" tall so you can bolt to the side of you box and to the base of the box. It wouldn't be pretty but it would be functional. Over the summer, I had my bed completely off the truck and I have far worse rust on mine than yours. I just put a few pieces of galvanized steel plate over top of the holes and bolted them down and then covered them with my plastic bed liner. you would never know it was like that unless you lifted the liner.
 


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