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Home/ Registry/ Ford/ Bronco/ 1992–1996/ “Big '92”/ Body Work and Rust Repair including drip rail R&R supermotors.net/registry/2896/79815

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Body Work and Rust Repair including drip rail R&R

From 1992 Ford Bronco “Big '92” — documented by Jeremy Millrood.

211 photos
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1992 Ford Bronco - Fenders trimmed to clear 37 inch swampers. need to do something to create a lip on the inner part of the fender so I can do a better job re… 1992 Ford Bronco - Fenders trimmed to clear the 37 inch swampers 1992 Ford Bronco - Another shot of trimmed drivers side rear fender. 1992 Ford Bronco - Close-up view of a vehicle's wheel well interior, showing fasteners and signs of wear. 1992 Ford Bronco - crumpled drivers side fender. 1992 Ford Bronco - close up of the crunched drivers side fender. 1992 Ford Bronco - shiny new (to me) fender from a Bronco and matching color..this was before it got trimmed. 1992 Ford Bronco - Old fender about to come off. 1992 Ford Bronco - accidentally cut into the tub while removing the old fender so I welded it up.. 1992 Ford Bronco - not the greatest job but it's not something anyone is going to see so it will do..I hit it with some primer before I put the new fender on. 1992 Ford Bronco - you can see the alignment pins for the fender behind the headlamp bezel. 1992 Ford Bronco - The undercarriage of a white vehicle displays significant rust and sealant degradation. 1992 Ford Bronco - Drivers side fender completely removed. In the lower right hand corner you can see the rubber duck bill for the cowl drain. 1992 Ford Bronco - post trim, the new fender is just sitting there..looks much better. 1992 Ford Bronco - getting everything bolted up. 1992 Ford Bronco - here it is with the lower mounting bolt in .you can tell something got tweaked when I bottomed out because the lower mounting hole on the n… 1992 Ford Bronco - side shot of how much it's bowed. 1992 Ford Bronco - lower mounting bolt that was giving me trouble..had to come back a grind off part of the tab so it wouldn't rub on the sliders. 1992 Ford Bronco - used a pop rivet to connect the inner plastic fender to the outer. the result is much better than the ugly bolts... 1992 Ford Bronco - Tailgate lip started to rust. I had this repaired once by a shop that replaced the outer skin. They obviously did a crap job so I'm going t… 1992 Ford Bronco - another shot of the rust on the tailgate lip. 1992 Ford Bronco - this is my attempt at a weld repair on the tailgate reinforcement this piece had completely cracked..not the cleanest work but it should be… 1992 Ford Bronco - more rust 1992 Ford Bronco - here are some of the products I used to fix the tailgate. Was able to get the oxford white duplicolor paint from a couple of different part… 1992 Ford Bronco - this was outer skin with the fascia removed..that entire strip where the added the new skin was rusting, luckily it didn't go all the way t… 1992 Ford Bronco - the lip was the worst..I had to do a ton of grinding to clean it up with a wire cup brush, then hit it with rust inhibitor. 1992 Ford Bronco - outer tailgate skin sanded and hit with rust inhibitor 1992 Ford Bronco - Car door panel with rust repair work, including primer and sealant application. 1992 Ford Bronco - shot of the lip of the tailgate. this took a lot of sanding to get it even. 1992 Ford Bronco - This photo shows a section of a vehicle's body panel with evidence of rust and repair work. 1992 Ford Bronco - Close-up of a vehicle body panel undergoing rust repair, revealing damaged metal and primer. 1992 Ford Bronco - Tailgate sanded and primed. not the greatest job, but at least there isn't any rust. 1992 Ford Bronco - A vehicle tailgate, prepped for repair, rests on sawhorses before a garage door. 1992 Ford Bronco - b-pillar passenger side right by the door jamb. You can see where the water coming in from the cracked rain gutter has caused it to rust fr… 1992 Ford Bronco - b-pillar seam..you can see rust forming in the crack 1992 Ford Bronco - PS - underneath the rain gutter. this is obviously rusted through. 1992 Ford Bronco - back of passenger side rain gutter, rust is the worst here. 1992 Ford Bronco - passenger side rain gutter and cracks. you can clearly see the rust bubbling up underneath the paint. 1992 Ford Bronco - passenger side access panel. this was from a previous attempt at repairing the cracks. 1992 Ford Bronco - Inside the access panel, looking at the back side of the rain gutter, passenger side.. You can see where all the rust has come through in t… 1992 Ford Bronco - another shot inside the passenger side sail panel..once I get it cleaned up, I'll douse the inside with rust inhibitor. 1992 Ford Bronco - inside of the passenger sail panel..look at all the rust..going to hit it with rust treatment. In hindsight it would have been a good idea… 1992 Ford Bronco - another shot of the sail panel inside towards the back 1992 Ford Bronco - passenger side drip rail..this side had about a 1/4 inch gap where it had rusted through at the top. 1992 Ford Bronco - a shot from the back of the passenger side drip rail before I started cleaning it up.. the grey stuff is JB weld that I had used to cover u… 1992 Ford Bronco - passenger side drip rail cleaned up..the rust was a lot worse than I thought. you can see the huge gap.I'm going to weld up the back and th… 1992 Ford Bronco - back of the drip rail.. 1992 Ford Bronco - shot from the inside of the sail panel, I was able to easily knock out the old reinforcement panels..you can already see the day light comi… 1992 Ford Bronco - another shot from the inside of the sail panel with the reinforcement panel removed...the will need to be cut out. 1992 Ford Bronco - this is on of the factory TSB kit reinforcement panels..the rust is mostly surface so I may actually be able to salvage it. at the very lea… 1992 Ford Bronco - both reinforcement panels 1992 Ford Bronco - the view with both panels removed..this was a lot worse than I thought. 1992 Ford Bronco - back of the sail panel, I ground out as much of the old seam sealer as I could..this was in pretty good shape. 1992 Ford Bronco - drip rail cleaned up with rust treatment applied..ready to repair.. 1992 Ford Bronco - Rust damage on the drip rail of a 1992 Ford Bronco, ready for repair. 1992 Ford Bronco - test fitting my reinforcement panel. 1992 Ford Bronco - started welding up the corner where the cracks were. 1992 Ford Bronco - good thing I had this spare fender was able to use it to cut my new reinforcement panels and other patches. 1992 Ford Bronco - welded and ground down. not the best job, but with the panels in place from the inside, it should be fine. 1992 Ford Bronco - passenger hole below the drip rail. It had rusted all the way through so I had to cut to clean metal to repair. this was after it had been… 1992 Ford Bronco - The door frame of a white vehicle shows signs of wear and tear, with rust and peeling paint evident. 1992 Ford Bronco - This is permatex product called cold weld. it has a sheer strength of 3000 psi once it is fully cured. I'll be using it to attach my reinfo… 1992 Ford Bronco - my homemade reinforcement panel. I'll be using this one on the passenger side. made from a piece of the old fender. 1992 Ford Bronco - huge hole from rust in the ps b-pillar 1992 Ford Bronco - here is where the sail panel meets the body, still need to do some cutting to clean it up. 1992 Ford Bronco - this area around the seam in the pillar was bad. going to need to do some cutting to get to clean metal so I can repair it. 1992 Ford Bronco - Significant rust damage is visible on the door jamb of a white vehicle. 1992 Ford Bronco - cut out all the bad material and ready to start patching the sail panel from the inside. 1992 Ford Bronco - all of the rusted metal cut out from the b-pillar. In hind sight I probably should have cut a bigger section out and used a larger patch, b… 1992 Ford Bronco - b-pillar primed over 1992 Ford Bronco - first patch in place. 1992 Ford Bronco - Ignore this. 1992 Ford Bronco - shot from the rear of the passenger side sail panel. 1992 Ford Bronco - one patch in the b-pillar. patch was cut out from the old fender 18 gauge and attached with the cold weld. 1992 Ford Bronco - second b-pillar patch in... 1992 Ford Bronco - the permatex cold weld sets up much more quickly that JB weld, so you have to work fast.. 1992 Ford Bronco - The photo shows a close-up of a vehicle's door hinge area, highlighting recent rust repair and painting. 1992 Ford Bronco - test fitting my patch for the roof..Initially I was going to, but I decided to weld this in place. the was a lot more rust here that I orig… 1992 Ford Bronco - here are y booger welds...no it's not pretty..but the the hole is closed up.. 1992 Ford Bronco - grinding down the welds..this took a while since I had to keep going back to re-welding spots I missed. 1992 Ford Bronco - getting closer. 1992 Ford Bronco - shot from the inside with both patches in place. at this point it is just the patch. I am going to add the reinforcement panel to both. 1992 Ford Bronco - Detail of a welded repair patch on vehicle bodywork, indicating rust repair. 1992 Ford Bronco - Close-up of rust and repair on a vehicle's body panel, with a canvas cover visible. 1992 Ford Bronco - this is about at good as it's going to get..need to put some primer on it so it doesn't start rusting again.. 1992 Ford Bronco - used seam sealer in the gutter, but didn't let it cure long enough. wound up having to remove most of it. 1992 Ford Bronco - Bodywork repair in progress, with masking tape applied to protect surrounding areas. 1992 Ford Bronco - getting the b-pillar ready for filler. 1992 Ford Bronco - had to touch up the seam again. 1992 Ford Bronco - Body panel repair work in progress, with masking tape and filler applied to a section of the vehicle. 1992 Ford Bronco - top reinforcement panel in place I put as much cold weld in there as possible. 1992 Ford Bronco - This is a close-up view of a section of a vehicle's underbody that has undergone repair work, with sealant applied. 1992 Ford Bronco - Detail of a section of automotive body work showing sealant and bracing. 1992 Ford Bronco - prepping the b-pillar..didn't work too well with my angle grinder, so I picked up a D/A sander from harbor freight..all I was hoping to do… 1992 Ford Bronco - A vehicle body panel is taped off and covered with newspaper, showing signs of repair work. 1992 Ford Bronco - Close-up of automotive body panel repair work, showing a seam and masking tape. 1992 Ford Bronco - rain gutter, almost done..need some cold weld to fill in the drip rail a bit. 1992 Ford Bronco - another gift from the rust Gods. This was the front of the drip rail, luckily nothing had gone through, so a little primer and some body fi… 1992 Ford Bronco - Masking tape protects vehicle bodywork during painting of the drip rail area. 1992 Ford Bronco - Body panel masked for repair work, with newspaper protecting surrounding areas. 1992 Ford Bronco - A car part is covered in tape and newspaper, ready for a paint job. 1992 Ford Bronco - harbor freight specials. I think I spent about $60 for both..the D/A sander has been great..haven't tried the sprayer yet, but it got decen… 1992 Ford Bronco - Interior shot of the b-pillar...it doesn't look pretty but hopefully the rust won't come back any time soon. 1992 Ford Bronco - Close-up view of underbody rust repair work, showing sealant and patched metal sections. 1992 Ford Bronco - roughed up the b-pillar with the D/A sander and some 80 grit..seemed to work pretty well. 1992 Ford Bronco - Body panel repair work in progress, showing filler and primer application. 1992 Ford Bronco - had to move the Bronco into the garage to paint. it was still a tight squeeze, even after losing 20lbs of air pressure in each tire . 1992 Ford Bronco - A white 1992 Ford Bronco is parked in a garage, equipped with a bull bar and large tires. 1992 Ford Bronco - getting the body filler in the seam..not sure if this is going to crack again or what but it should be good for a while. 1992 Ford Bronco - Close-up of a vehicle's body panel showing repair work with body filler and tape. 1992 Ford Bronco - rain gutter almost done. 1992 Ford Bronco - Close-up of bodywork repair, showing primer and filler applied to the drip rail area of a vehicle. 1992 Ford Bronco - patched the lower hole, used pop rivets and cold weld..hopefully I didn't lose too much rigidity here. 1992 Ford Bronco - all primed up inside...hesitant to put the cover on, would still like to get some more rust inhibitor sprayed in there, but you can see fro… 1992 Ford Bronco - Seam sealant applied to the underbody of a vehicle. 1992 Ford Bronco - This photo shows bodywork in progress on a vehicle, with primer and filler applied to the door jamb area. 1992 Ford Bronco - Close-up of a vehicle body panel undergoing rust repair and bodywork. 1992 Ford Bronco - Close-up of bodywork and primer on a vehicle's drip rail, indicating repair work. 1992 Ford Bronco - Area of car body showing primer and rust, likely undergoing repair. 1992 Ford Bronco - A white Ford Bronco with a soft top and off-road tires is parked in a garage, with another vehicle in the background. 1992 Ford Bronco - sail panel primed, ready to paint. 1992 Ford Bronco - A vehicle body panel is covered in blue masking tape, indicating repair work is in progress. 1992 Ford Bronco - one final prime before painting. I used the self ething primer. 1992 Ford Bronco - Automotive body panel being prepped for repair with masking tape applied. 1992 Ford Bronco - This was after a couple of coats of base. I used automotive touchup paint in an aerosol can. At $20 a can, it wasn't cheap, but tit was fac… 1992 Ford Bronco - A vehicle body panel is masked off and covered with plastic sheeting, ready for painting. 1992 Ford Bronco - A vehicle body panel is covered in masking tape and plastic sheeting, indicating preparation for painting. 1992 Ford Bronco - The rain gutter came out much better than I thought it would. 1992 Ford Bronco - A vehicle body panel is covered in plastic sheeting, likely for protection during repairs or painting. The SuperMotors logo is visible in t… 1992 Ford Bronco - I'll get another shot with the tape and everything removed. all in all it turned out pretty good..At least for a first timer. In hind site,… 1992 Ford Bronco - you can see the difference between the two paints where it was taped off. Plan is to feather the new paint in then I will re-shoot the whol… 1992 Ford Bronco - rain gutter came out pretty good, you can see some waves, but it looks fine from 10 ft away... 1992 Ford Bronco - not happy with the uneven way the paint looked, I sanded to whole pillar again and re-primed to get everything blended in. I have a few swi… 1992 Ford Bronco - Newspaper and masking paper protect the interior of a vehicle undergoing body work and rust repair. 1992 Ford Bronco - primer dried, ready for 1st coat of paint. 1992 Ford Bronco - A vehicle body panel is masked and covered with newspaper, indicating repair work is in progress. 1992 Ford Bronco - paint down, time for clear coat. 1992 Ford Bronco - looks much better with the pain blended. 1992 Ford Bronco - Close-up of the drip rail area on a white 1992 Ford Bronco, showing recent body work. 1992 Ford Bronco - Close-up view of the drip rail on a white SUV, showing areas of repair and potential rust. 1992 Ford Bronco - Rain gutter finished. 1992 Ford Bronco - passenger side done with the top back on..looks good. 1992 Ford Bronco - Close-up of the side of a 1992 Ford Bronco, showing the door and soft top. 1992 Ford Bronco - This is the front of the driver's side rain gutter. Willing to bet that hole is all the way through..yay more rust. 1992 Ford Bronco - Close-up view of rust forming on the edge of a white vehicle's door. 1992 Ford Bronco - drivers side sail. I don't think it's as bad as the other side, but the paint is going to have to come off to find out.., 1992 Ford Bronco - Rust is visible along the seam of a white vehicle panel, indicating potential body work issues. 1992 Ford Bronco - Rust is visible on the lower body panel of a white vehicle, with another vehicle in the background. 1992 Ford Bronco - Rust damage is visible along the drip rail of a vehicle, indicating repair needs. 1992 Ford Bronco - The drip rail on this vehicle shows significant rust and damage, indicating a need for repair. 1992 Ford Bronco - This image shows extensive rust damage on a vehicle's body, indicating a need for repair. 1992 Ford Bronco - gap in the seam on the drivers side rain gutter. you can see how the seam has separated, and I'm pretty sure rain is dripping through the h… 1992 Ford Bronco - Detail of rust damage on a vehicle's drip rail, marked for repair. 1992 Ford Bronco - about to open the drivers side..this one had rivets in it and one screw...can't wait to how the inside looks. 1992 Ford Bronco - not great, but not as bad as I thought..your can see the reinforcements panels are starting to rust.. 1992 Ford Bronco - another view of the rust on the drivers side. 1992 Ford Bronco - at least the rust doesn't seem to be as wide spread as it was on the passenger side. 1992 Ford Bronco - picture down inside the b-pillar you can see the rust stain running towards the floor. 1992 Ford Bronco - The interior of a vehicle shows significant rust damage along a metal channel. 1992 Ford Bronco - Severe rust and corrosion are evident on this metal seam, indicating significant body work is needed. 1992 Ford Bronco - fortunately, both of the reinforcement panels pulled right off..there goes the top..and I think I'll be able to reuse the bottom one.. 1992 Ford Bronco - this is what was behind the reinforcements. the rust was all on the surface. would have been nice if I had a media blaster to clean this of… 1992 Ford Bronco - Extensive rust damage is visible on this vehicle's body, indicating significant deterioration. 1992 Ford Bronco - again, whoever did the repair before, did a piss poor prep job.. 1992 Ford Bronco - cleaning up the inside..not sure if I'm going to have to weld up the corner yet or not. there are a number of holes in there from where the… 1992 Ford Bronco - Rust damage is visible on the drip rail and adjacent bodywork of the vehicle. 1992 Ford Bronco - these gray blobs are the remnants of the holes from my old soft top bracket. will smooth them down then cover over with filler and seam sea… 1992 Ford Bronco - This photo shows extensive body work and rust repair on the upper corner of a vehicle's body. 1992 Ford Bronco - rear shot of the drivers side rain gutter, the previous shot that did this repair did a real crap job, the old sealer was still in the gutt… 1992 Ford Bronco - cleaning up the old filler. 1992 Ford Bronco - The interior of a white vehicle reveals a roll cage and evidence of bodywork on the door frame. 1992 Ford Bronco - Close-up of a vehicle's door frame showing areas of rust repair and body filler application. 1992 Ford Bronco - bought the napa seam sealer product. came in beige, not a big deal since I'll be painting it. Applied it to the corner of the cab, this stu… 1992 Ford Bronco - underneath the rain gutter. 1992 Ford Bronco - front gap filled. 1992 Ford Bronco - Body filler is being applied to the drip rail of a 1992 Ford Bronco during rust repair. 1992 Ford Bronco - front of the rain gutter. this came out ok. 1992 Ford Bronco - Body work in progress on a vehicle's door frame, showing areas of rust and filler application. 1992 Ford Bronco - Auto body repair work in progress on a vehicle panel, showing primer and filler. 1992 Ford Bronco - This photo shows body work being done on a vehicle's drip rail, with visible filler and primer. 1992 Ford Bronco - Close-up of vehicle bodywork undergoing repair, revealing primer and filler on a damaged section. 1992 Ford Bronco - Bodywork and rust repair in progress on a vehicle's drip rail, with masking tape applied. 1992 Ford Bronco - seam sealer in the drivers side rain gutter. 1992 Ford Bronco - shot of the drivers side b-pillar after it was primed. 1992 Ford Bronco - Vehicle body panel prep work, showing newspaper and tape protecting interior during body repair. 1992 Ford Bronco - Two automotive trim pieces are shown with a ruler for scale, possibly for a repair or restoration project. 1992 Ford Bronco - Two automotive trim pieces are shown with a ruler, suggesting they are parts for repair or replacement. 1992 Ford Bronco - Two green trim pieces are laid out and measured with a metal ruler against a brown background. 1992 Ford Bronco - Metal trim pieces measured with a ruler. No vehicle is visible in the photo. 1992 Ford Bronco - Bodywork is underway on a vehicle, with primer and masking tape visible. 1992 Ford Bronco - A close-up of a vehicle's body panel shows taped newspaper and a seam, suggesting repair work. 1992 Ford Bronco - A vehicle body panel is covered in masking tape and newspaper, indicating repair work is in progress. 1992 Ford Bronco - Vehicle body panel covered in newspaper and tape, undergoing preparation for repair or painting. 1992 Ford Bronco - Newspaper is used to mask off a vehicle's body panel during a paint job. 1992 Ford Bronco - Close-up of a vehicle body panel undergoing repair and painting. 1992 Ford Bronco - Detail of a white vehicle body panel undergoing repair, with masking tape and newspaper protecting surrounding areas. 1992 Ford Bronco - Detail of body panel repair, showing masking tape and primer on a vehicle part. 1992 Ford Bronco - Newspaper is used to mask off a vehicle body panel during repair work. 1992 Ford Bronco - Automotive repair supplies including sealants and adhesives are laid out on a workbench. 1992 Ford Bronco - Close-up of the door frame seal on a white 1992 Ford Bronco, showing areas of rust repair. 1992 Ford Bronco - Detail of a vehicle's door seal and surrounding bodywork. 1992 Ford Bronco - Detail of a vehicle's door frame, showing the seal and surrounding bodywork. 1992 Ford Bronco - Close-up of a white vehicle's door seam, showing evidence of repair work and a black rubber seal. 1992 Ford Bronco - Detail of a white vehicle's bodywork, showing a wooden support structure near the roof drip rail. 1992 Ford Bronco - Detail of a vehicle's door frame and seal, with a Supermotors.net watermark. 1992 Ford Bronco - Detail shot of the door frame and interior of a vehicle, focusing on the weather stripping and surrounding metal. 1992 Ford Bronco - Close-up view of the vehicle's undercarriage, showing repair work and undercoating. 1992 Ford Bronco - Close-up view of underbody chassis repair, showing sealant application and structural components. 1992 Ford Bronco - The side profile of a white 1992 Ford Bronco reveals its interior and a brown soft top, with camouflage seat covers visible. 1992 Ford Bronco - This white SUV features a brown soft top and camouflage seat covers, seen from the side. 1992 Ford Bronco - side by side comparison of the passenger before and after the rust repair and body work.