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Thoughts on some rust repair


armadillon

Member
Joined
Aug 17, 2011
Messages
945
Reaction score
12
Points
18
Location
Austin, TX
Vehicle Year
93
Make / Model
Ford
Engine Size
3.0L
Transmission
Automatic
I had some rust eating through the area right above the drip rails on my cab. Looks like somebody tried shoving Bondo into the holes and didn't realize that it wouldn't stop the rust. I removed the headliner and could see where the rust stopped inside.

After cutting out sections of the drip rail and edge of the roof, I used a bit of the bondo-mesh and filled in the areas. On the other side I cut the rust area out completely and filled in with Great Stuff insulation just for a backing. After that I've covered that area with bondo (the insulation was to prevent having to use a ridiculous amount of filler.)

Once I sand it down smooth I was going to hit it with 2-3 coats of primer followed by 4-5 coats of Duplicolors Ford Performance White followed by another couple of coats of clearcoat.

I would have preferred to weld it but I don't have access to a welder. Do you think my method of rust repair will work?
 

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