Jeremy Millrood > 1992 Ford Bronco > open folder Body Work and Rust Repair including drip rail R&R

Fenders trimmed to clear 37 inch swampers. need to do something to create a lip on the inner part of...
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Fenders trimmed to clear the 37 inch swampers
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Another shot of trimmed drivers side rear fender.
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crumpled drivers side fender.
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close up of the crunched drivers side fender.
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shiny new (to me) fender from a Bronco and matching color..this was before it got trimmed.
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Old fender about to come off.
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accidentally cut into the tub while removing the old fender so I welded it up..
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not the greatest job but it's not something anyone is going to see so it will do..I hit it with some...
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you can see the alignment pins for the fender behind the headlamp bezel.
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Drivers side fender completely removed. In the lower right hand corner you can see the rubber duck b...
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post trim, the new fender is just sitting there..looks much better.
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getting everything bolted up.
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here it is with the lower mounting bolt in .you can tell something got tweaked when I bottomed out b...
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side shot of how much it's bowed.
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lower mounting bolt that was giving me trouble..had to come back a grind off part of the tab so it ...
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used a pop rivet to connect the inner plastic fender to the outer. the result is much better than th...
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Tailgate lip started to rust. I had this repaired once by a shop that replaced the outer skin. They ...
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another shot of the rust on the tailgate lip.
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this is my attempt at a weld repair on the tailgate reinforcement this piece had completely cracked....
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more rust
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here are some of the products I used to fix the tailgate. Was able to get the oxford white duplicolo...
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this was outer skin with the fascia removed..that entire strip where the added the new skin was rust...
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the lip was the worst..I had to do a ton of grinding to clean it up with a wire cup brush, then hit ...
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outer tailgate skin sanded and hit with rust inhibitor
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shot of the lip of the tailgate. this took a lot of sanding to get it even.
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Tailgate sanded and primed. not the greatest job, but at least there isn't any rust.
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b-pillar passenger side right by the door jamb. You can see where the water coming in from the crack...
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b-pillar seam..you can see rust forming in the crack
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PS - underneath the rain gutter. this is obviously rusted through.
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back of passenger side rain gutter, rust is the worst here.
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passenger side rain gutter and cracks. you can clearly see the rust bubbling up underneath the paint...
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passenger side access panel. this was from a previous attempt at repairing the cracks.
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Inside the access panel, looking at the back side of the rain gutter, passenger side.. You can see w...
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another shot inside the passenger side sail panel..once I get it cleaned up, I'll douse the inside w...
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inside of the passenger sail panel..look at all the rust..going to hit it with rust treatment. In h...
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another shot of the sail panel inside towards the back
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passenger side drip rail..this side had about a 1/4 inch gap where it had rusted through at the top.
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a shot from the back of the passenger side drip rail before I started cleaning it up.. the grey stu...
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passenger side drip rail cleaned up..the rust was a lot worse than I thought. you can see the huge g...
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back of the drip rail..
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shot from the inside of the sail panel, I was able to easily knock out the old reinforcement panels...
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another shot from the inside of the sail panel with the reinforcement panel removed...the will need ...
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this is on of the factory TSB kit reinforcement panels..the rust is mostly surface so I may actually...
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both reinforcement panels
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the view with both panels removed..this was a lot worse than I thought.
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back of the sail panel, I ground out as much of the old seam sealer as I could..this was in pretty g...
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drip rail cleaned up with rust treatment applied..ready to repair..
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test fitting my reinforcement panel.
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started welding up the corner where the cracks were.
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good thing I had this spare fender was able to use it to cut my new reinforcement panels and other p...
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welded and ground down. not the best job, but with the panels in place from the inside, it should be...
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passenger hole below the drip rail. It had rusted all the way through so I had to cut to clean metal...
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This is permatex product called cold weld. it has a sheer strength of 3000 psi once it is fully cure...
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my homemade reinforcement panel. I'll be using this one on the passenger side. made from a piece of ...
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huge hole from rust in the ps b-pillar
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here is where the sail panel meets the body, still need to do some cutting to clean it up.
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this area around the seam in the pillar was bad. going to need to do some cutting to get to clean me...
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cut out all the bad material and ready to start patching the sail panel from the inside.
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all of the rusted metal cut out from the b-pillar. In hind sight I probably should have cut a bigger...
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b-pillar primed over
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first patch in place.
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Ignore this.
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shot from the rear of the passenger side sail panel.
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one patch in the b-pillar. patch was cut out from the old fender 18 gauge and attached with the cold...
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second b-pillar patch in...
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the permatex cold weld sets up much more quickly that JB weld, so you have to work fast..
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test fitting my patch for the roof..Initially I was going to, but I decided to weld this in place. t...
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here are y booger welds...no it's not pretty..but the the hole is closed up..
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grinding down the welds..this took a while since I had to keep going back to re-welding spots I miss...
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getting closer.
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shot from the inside with both patches in place. at this point it is just the patch. I am going to a...
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this is about at good as it's going to get..need to put some primer on it so it doesn't start rustin...
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used seam sealer in the gutter, but didn't let it cure long enough. wound up having to remove most o...
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getting the b-pillar ready for filler.
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had to touch up the seam again.
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top reinforcement panel in place I put as much cold weld in there as possible.
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prepping the b-pillar..didn't work too well with my angle grinder, so I picked up a D/A sander from ...
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rain gutter, almost done..need some cold weld to fill in the drip rail a bit.
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another gift from the rust Gods. This was the front of the drip rail, luckily nothing had gone throu...
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harbor freight specials. I think I spent about $60 for both..the D/A sander has been great..haven't ...
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Interior shot of the b-pillar...it doesn't look pretty but hopefully the rust won't come back any ti...
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roughed up the b-pillar with the D/A sander and some 80 grit..seemed to work pretty well.
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had to move the Bronco into the garage to paint. it was still a tight squeeze, even after losing 20l...
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getting the body filler in the seam..not sure if this is going to crack again or what but it should ...
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rain gutter almost done.
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patched the lower hole, used pop rivets and cold weld..hopefully I didn't lose too much rigidity her...
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all primed up inside...hesitant to put the cover on, would still like to get some more rust inhibito...
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sail panel primed, ready to paint.
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one final prime before painting. I used the self ething primer.
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This was after a couple of coats of base. I used automotive touchup paint in an aerosol can. At $20 ...
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The rain gutter came out much better than I thought it would.
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I'll get another shot with the tape and everything removed. all in all it turned out pretty good..At...
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you can see the difference between the two paints where it was taped off. Plan is to feather the new...
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rain gutter came out pretty good, you can see some waves, but it looks fine from 10 ft away...
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not happy with the uneven way the paint looked, I sanded to whole pillar again and re-primed to get ...
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primer dried, ready for 1st coat of paint.
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paint down, time for clear coat.
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looks much better with the pain blended.
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Rain gutter finished.
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passenger side done with the top back on..looks good.
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This is the front of the driver's side rain gutter. Willing to bet that hole is all the way through....
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drivers side sail. I don't think it's as bad as the other side, but the paint is going to have to co...
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gap in the seam on the drivers side rain gutter. you can see how the seam has separated, and I'm pre...
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about to open the drivers side..this one had rivets in it and one screw...can't wait to how the insi...
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not great, but not as bad as I thought..your can see the reinforcements panels are starting to rust....
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another view of the rust on the drivers side.
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at least the rust doesn't seem to be as wide spread as it was on the passenger side.
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picture down inside the b-pillar you can see the rust stain running towards the floor.
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fortunately, both of the reinforcement panels pulled right off..there goes the top..and I think I'll...
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this is what was behind the reinforcements. the rust was all on the surface. would have been nice i...
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again, whoever did the repair before, did a piss poor prep job..
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cleaning up the inside..not sure if I'm going to have to weld up the corner yet or not. there are a ...
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these gray blobs are the remnants of the holes from my old soft top bracket. will smooth them down t...
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rear shot of the drivers side rain gutter, the previous shot that did this repair did a real crap jo...
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cleaning up the old filler.
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bought the napa seam sealer product. came in beige, not a big deal since I'll be painting it. Applie...
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underneath the rain gutter.
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front gap filled.
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front of the rain gutter. this came out ok.
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seam sealer in the drivers side rain gutter.
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shot of the drivers side b-pillar after it was primed.
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side by side comparison of the passenger before and after the rust repair and body work.
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