I just posted a question in the Expedition forum about frame rust on my 2000 EB, but perhaps this is a better forum. Just like the posts above, the body/paint looks good from the outside, but underneath the unibody frame rails above the rear wheels are rotting away. A body shop told me it would be difficult to fix - does anyone here have any advice?

Thanks.

 

Yea my rear shackles rusted thru @ 270,000 miles. So did the lower body panels and both rockers. Fixing them now. What a PITA. I just cut the panels above the body line and welded in replacements. Get your replace metal from Ray bucks, - LMK is to expensive.

 

Anybody looking for rockers, check with Parker Metal Products out of Terentum Pa.( Pittsburgh).
http://www.pmpautoparts.net/

I just replaced mine on a 2001 Supercrew for $135 each. Full length,front to rear, top to bottom.

The website isn't very good, e-mail or call them to see what they have.

 

Yep Jbrew, Raybucks had all the sheet metal I needed! My friend who did the welding and painting says they fit PERFECT! Raybucks has quick shipment and were good on the phone with questions too!

 

What did you use to cut the old one's out? I have to do this to my 98 Reg Cab, so hopefully easier, however I never done it before. looks like you got a good job?, what did you use to smooth the weld? die Grinder?

Any more hints and info will help me, thanks

 

skizriz,
Is that the welder you used at the bottom of the picture? It looks like a small electric arc only unit. Is that right and was it adequate? I've been thinking it might make sense to buy one for the rocker arms and some other small jobs (bed) on my F150 and another vehicle. I have no welding experience but am willing to learn and I'm thinking an "entry level" welder might pay for itself with one or two jobs.

 

http://www.lmctruck.com/icatalog/fe/full.aspx?Page=15

 

You can't find the rocker for the passenger side for a 97-98 3 door truck. I tried awhile back and couldn't find them. I had to redo the whole thing myself because of an accident that someone else got into in my truck. Wrecked the whole bottom of panels down the passenger side. You can get just the part rocker on passenger side but not the whole thing.

 

Sure you can. - I did a few years ago, - here -

http://raybuck.com/i-154682-1997-03-...-doors-rh.html

 

I don't know if it is just me, but for some reason that panel just doesn't look right at all.

 

Really, - it fit my 98 3 door. I did the drivers as well. Also the lower bed panels on both sides. They were cheaper than LMC back then.

 

It's probably a little Mig. You can get those cheap @ Harbor Freight, -just don't use the wire that comes with, -it's terrible. A cheap Mig (90amp) w/Lincoln wire is panel welding capable. Not the best set up, but doable. Weld 1/2" at a time, change location or cool with compressed air, then damp sponge if your in a hurry. Rockers aren't that big of a deal, panels can warp easy if your not careful, - specially the rear bed panels.

 

I was actually wondering how important using the shielding gas in MIG is for these kinds of jobs, versus the flux core approach. I got a welding book and started reading it, and it seems the shielding gas makes it easier to keep the welds clean. However, I guess the gas doesn't do much good with outside jobs, and of course adding the gas is more expensive. The unit in skizriz' picture looks like a flux core unit to me. Some of the rigs apparently are "MIG-ready" , i.e. gas can be added by adding a regulator and gas bottle at a later date and meanwhile it can be used with flux core wire. That is the approach I was thinking of. So far, I've looked at Harbor Freight, Tractor Supply and Sears. Tractor Supply sells a Hobart 125 that looks good, but a good more expensive than HF.

 

EDIT: User above never responded, - Ignore List.

 

I just discovered the rusted out rockers under my 2001. How have you guys been doing this? Are you cutting out the whole rocker or cutting out the worst of the rust and welding the new rocker panel over the old panel?

Last time I did this was on a 1980 F150 for the rockers and cab corners. I cut the worst rust out sand blasted the rest and applied the new panels over the old. I got about 6 more years from the truck before rust overtook the frame.