Severe rust repair

[thrdeye]

So, for those of you that have seen it, the Excursion is pretty rusty on the underside. I like the thing though, so I'd like to keep it around a while and would be willing to spend a little money to do so. Obviously if someone made something similar to the Excursion, it would likely be best to bit the bullet and replace it, but A) No one does B)they would be too expensive anyway C)a truck with a camper doesn't work for me and D)I've already put some money into the Excursion to keep it road worthy.

Is it possible to fix and repair rust that is pretty severe? It's probably bad enough that it would require some cutting and welding in some places and that's definitely above my pay grade. I'd also need to replace the running boards.

So, anyone ever bring one back from the grave?

[jcox07]

Running boards would probably be an easy fix as long as the attachment points are still solid and if not a good fabricator could easily make some attachment points to weld in.

[sentrase]

1. It can absolutely be done, but will be an enormous time suck
2. Unless you do the welding yourself, it will never be cost effective.

It makes sense if not welding it would keep it from being driven, i.e. seat falling through the floor.

[John Brown]

Running boards would probably be an easy fix as long as the attachment points are still solid and if not a good fabricator could easily make some attachment points to weld in.

still solid in that area if I remember correctly...

[MARKP]

Any body shop can cut out and weld new stuff in. Usually once it starts, it's just a matter of trying to stay ahead of it.

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[benk]

Yeah. Cutting and welding then sealing is the way to go. I've got a similar project on our classic beetle but it's much simpler to pull the body off the frame and have full access than your truck.

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[oldmuscle69]

RUST? Is that what you want fixed? Do you have the removal tools? And do you have the weld tools in your garage? What about replacement metal needed for the repairs. I can do that shit and you can learn!! Poss might need shaping fixture (English wheel)

[thrdeye]

Thanks for the offer Bob, but no tools and no space. It's not body panel stuff, it's all structural underneath the thing.