My DIY Weld Free Rocker Panel Rust Repair
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- Опубликовано: 24 июл 2024
- This wasn't easy, and the results aren't perfect, but the "After" is a thousand times better than the "Before."
00:29 Step 1: Rust Removal
01:33 Step 2: Rust Converter
01:57 Step 3: Rubberized Undercoating
02:30 Step 4: A lot of Bondo Glass, Bondo Mesh And Sanding
13:47 Step 5: More Sanding
15:06 Step 6: Gold Body Filler and Sanding Round 1
18:41 Step 7: Gold Body Filler and Sanding Round 2
20:12 Step 8: Glazing & Spot Putty and Sanding
22:02 Step 9: Gray Filler Primer
23:50 Step 10: Color Match Paint
25:17 Step 11: Clear Coat
Here are @chrisfix 's product links:
Products:
Glass Filler: amzn.to/2zdSA6o
Gold Filler: amzn.to/2xtzWTx
Adhesive Remover: amzn.to/2zduvfU
Sandpaper: amzn.to/2gQph2b
Spot Putty: amzn.to/2yauidi
Body Patch Mesh: amzn.to/2iGmSri
Polish: amzn.to/2zcSOe2
Dust Mask: amzn.to/2xu4017
Sanding Block: amzn.to/2iaKNLM
Paint:
Rust Converter: amzn.to/2iGmFo0
Rubberized Undercoating: amzn.to/2hmXD9N
Filler Primer: amzn.to/2xuIrxI
Color Matching Paint: amzn.to/2IYlFEP
Duplicolor Clear Coat: amzn.to/36DR7EM
Also here is the link to the respirator I HIGHLY RECOMMEND you get before getting into the sanding marathon that is rust repair.
Respirator: amzn.to/3mn07EB
Respirator Filters: amzn.to/2FUoDgF - Авто/Мото
Nice repair! Here are some suggestions for future repairs from my experience:
1. A tip i'd suggest is using fiberglass itself for the repair, I believe it would be much easier to get the shape back using it. Besides, from what I've heard fiberglass holds on to metal stronger compared to fillers. You can find a great youtube video covering using my mentioned by 4diyers, I like his method a lot, and used it for repairing a rust hole in my car's wheel arch.
2. I believe that a rust converter is a great idea in the front of the repair too, since from what I've observed it's unlikely that you'll take all of the rust off - some of it will stay in the pitting, and might come back if left untreated. If you decide on using it, just make sure to not sand through it, it needs to stay undamaged.
3. I don't recommend using a wirewheel attachment for removing rust - I've observed that it polishes some of it, and it looks like clean metal, when in reality sometimes if you'd hit the spot with a hammer you'd find that a chunk of rust would fall off. I'd suggest using a sanding attachment instead, that way you won't be doing any rust polishing :)
4. About the rubberized undercoating: I'm not sure if I'd want to use it, and I have not used it on any of my repairs. The reason is that unless it's applied over clean painted metal (rust converters need a top coat usually, the rubberized undercoating might not be a good substitute for paint), they trap moisture and accelerate rust, there are multiple youtube videos talking about this issue.
I am by no means a professional, it's just something I've gathered from reading countless forums, and watching youtube videos. Good luck on your future repairs, you'll get even better! :)
Hey there Evaldash! Thanks so much for all the tips!
It actually looks pretty darn good.
Thanks for that!
I thought you did a great job! Also huge props for even trying this on your own. To top if off you made me laugh a couple times when you said, "As you can see my hole is quite large." That's what she said and then again when you said, "I have the runs." I was dying. Great video!
Hi Jiva! I tried so hard on this, I've got some great advice from the comment section, so if I ever do have to do this again it hopefully will come out a little better. Thanks for watching =)
Great instructions for being new at this. You just showed the average person that not everything is pretty at first. Their will always be struggles on every job. It's all about the end product. You did great
Thank you Shane!
Thanks for the vlog. This is going to help more people than you think.
Aww thanks for saying that G!
Screw in a thin piece of sheet metal. Once cover with fiberglass bonds and it'd hardened, take screws out and fill holes
I use Eastwoods Internal Frame Coating to convert and prevent rust on the inside of rocker panels.
It has a flexible tube with a spray tip at the end which allows you to insert the tube into the rocker panels, and then saturate the area inside completely.
If you blow up a balloon and put it in the loose area it will give enough resistance to put the fiberglass resin in place. Then when you finish just pop the balloon and pull it out the back.
Wow that's a good idea!
You go girl! I'm getting ready to do the same thing on my old truck
Read through the comments because there are some good tips to be found! Good luck!
How did it go!!
This video had me laughing out loud thank you for sharing and sticking with the video recording! Love the commiseration.
Hi Elliot! Yeah I was ready to give up so many times. We just noticed some more rust pop up down there, but not on any of the spots I "fixed" so I'll be out there at it again soon. Thanks for watching =)
This is great because you show how frustrating it can be when you are not a pro.
So frustrating, lol.
Thanks for the positive reinforcement! I’ll get on my project soon!
I’m inspired TY. I’ve been nervous to start this on my 88 YJ. So I see now how good it will look TY so much!!!
You did it again! Way to be to be persistent. You can do anything with that kind of determination
Admired the perseverance doing something either everyone is going to complain you should “done correctly” or nit pick.
You took on the task, figured it out along the way and it came out great
You have my respect.
We have the same vehicle but they have gone up in value and I’m going to see how much for them to weld on the 2 pieces
The welding is the way to go for sure. We just didn't have the $ for it unfortunately. This 4runner is still going strong, and tbh my husband has kind of commandeered it, it just runs so great.
@@samechick those things are tough, aside from rust and lower ball joints nothing to really worry about
I'm about to have a go at some rust on my Hilux, if it looks as good as yours I will be more than happy.
Thanks for the inspiration.
Seriously, if I can do it you can do it. Good luck!
THANK YOU! You're persistence has motivated me! This is the way when your car is worth as much as the repair lol! Thanks again
Your**
Let me know how it turns out!
This is what I did with my rockers except first I took fiberglass resin and mat to hold the bondo in the hole. As soon as it hardens it will sand right down.
Dude on my 70s toyota the rockers are gone lmao 🤣 I think ima do fiberglass for sure
Another option for a quick fix and you can consider me a hack but alot of people will clean it up like you did at the beginning of the video then fill the hole with expanding foam and cut it down to a workable shape then apply bondo over the expanding foam. i have done it in the past with stuff just to keep it going its not proper but itll work to get a few extra years out of something that is otherwise safe to drive.
This was such a great video really enjoyed watching it your perseverance is amazing
Honestly if felt like a punch to the gut when I started sanding and most of everything there just disappeared. But nothing left to do than to keep trying! Thanks for watching Brian =)
thx very much,much respect for your perseverance,and like you said thousand time better than it was
Thanks for the kind words Mok!
For never having done this before, I think you did an awesome job. I may have tried putting the mesh on the outside rather than doing it from the inside.
I was in way over my head. If I had it to do over again, I may try to shove some sort of plastic pipe or something in that space just so I had something in there to put the filler on top of. Thanks for checking in Mike!
@@samechick I have a 99 Silverado and the drivers side same spot as yours is in the same shape. I hate bodywork and not very good at it but I am going to attempt it anyway using panel bond and body steel. I like mechanically fixing it, that I am good at. LOL!
@@mikechristie7226 You've got this!
Body shops... I took my Mustang to a body shop and they said my car was beyond repair.... Funny thing is my frame is still good plus it has stiffners that support the cars strutural integrity... So I will be doing like you and be repairing what needs to be done. You can even buy new car panels with your own model !
Good luck! You really get an amazing feeling of accomplishment once you are done, even if it's not perfect =)
You did a great job ! Got creative and got it done. Good for you !
Got creative is the nicest way of putting it! Thanks for watching =)
Nice video I also have a 3rd gen with rusty rockers. Hopefully I’m able to tackle this down myself
If I can do it ANYONE can do it. But, prepared to be frustrated a bit. And please do wear the respirator!
What a lot of work! I respect the work put in.Don’t know if you plan to do more but if you do they make body files and plains that allow fast shaping of the fillers when they’re partially hardened(still soft). These files and planes look similar to a cheese grater. I use them with filler and like them a lot.
You're Awesome! You did a great job! I feel your frustration but couldn't stop laughing when you stuck the rubber glove in! 🤣 but it worked! Good for you! Congrats! I might try this since my rocker panels are rocked with rust too.
Thank you for the kind words Barbara! And thanks for watching =)
Edit: You can do this too! It is a bear of a project but it can be done!
@@samechick Thank you so much! 😊
My 4runner’s rockers look almost identical. Wow. This is an amazing fix especially since you’re like me!
Make sure you use the expanding foam trick some have suggested, it would have saved me a bunch of time and stress if I'd thought of it then.
@@samechick That's smart. I have identical issues in all 4 corners and in the 2 rear cab corners
Looks like your patience payed off
It did! It was rougher than my other rust repair video but slow and steady wins the race I guess. Thanks for watching!
From what I’ve seen online there’s four ways to fix rust no holes. Spray foam, Bondo, wielding, and slip on covers. I thought we’ll why not try all of them at once? Gonna be expensive and time consuming but worth trying out.
People need to stop with saying oh it attracts water and makes it worse, it's obviously an older car not meant to last forever, it's a cheap fix to make it look better until ya drive it into the ground ffs!!😂 She did an awesome job if you ask me!
Thanks Lisa! It really is so much better than it was!
People do not need to stop saying it attracts water. I came here to see what I would need to do to fix my panels on a 2005 Tahoe. I would like to get another 100000 miles out of it. Using materials that attract water will not get me there. The fact that people are mentioning that is a great thing. It's not putting down the original video, it's adding to the content for others who are here for the same reason.
I would have suggested to cut some stove pipe tin and gorilla glue it over the big holes. Easier and much less messy and use of bondo.
Beautiful job. Amazin. 👍
Thank you!
You know what sister, if it looks good from across the street then it’s good for a work car!
Looks better than the rust for sure! 👍
Agreed, and that's all that matters really. Thanks for watching DjDestiny =)
Great job...could you please let me know that what all materials you bought for this and an approximate cost
All the products with links to amazon are in the description. I think altogether everything might be around $200 USD. I think I almost ran out of that first filler (the glass filler) so I'd recommend getting two of those just to be safe. Also, I'd buy double the sand paper since I was running low on that too.
You did an amazing job!!
Thank you Mike!
😎 you can be a great teacher motebatin others .this is how I got my driver's license. With someone just like you motebatin me that I can do it .and got my license first try. You are awesome.
Awwww thank you jocelyn!
Lemme put it this way: if it worked it ain't stupid. Good job for a first try.
Just did this,, but I sprayed foamed Inside after the black coating! Gives the filler alot to hold onto and a good staring shape
Good for you!
I'm going to give this a try. 2010 Milan with the rockers rotting. Maybe I can get it done in a day
You could have filled the hole with foam spray first to fill the void then add your fiber paper and bondo anyway great job
Great video. Was wondering.. What primer would you suggest on the grinded area of a welded on rocker panel? I don't plan on paint for several months down the road.
Hi jay! I used the Bondo brand primer >> www.amazon.com/Bondo-720-Finish-Aerosol-Primer/dp/B000ZO2ABI >> I'm not a pro at all so I wouldn't know which would be best for long term. Good luck on your project though!
On the cheap end Bondo glass is good to work with you would want to make a template of the damage area with waxed paper and Bondo glass the template hold it firmly to the area and your done!!!!😁
Good job !
Thanks!
I know a pro body guy (best I’ve ever met) and he even ends up with runs in a rattle can job.
Not sure I'm going to follow it but loved your honesty 🙂
There are some helpful tips in the comments section here, so I'm pretty sure I wouldn't do it quite the same way if I was going to tackle a job like this again.
@@samechick Yes, on a smaller hole you could get away with it. To keep the mesh in place first place some bondo on the inside lip and then set it into that. Maybe a couple of self tapping screws into the mesh to act like handles so you can pull it towards yourself.
I'm doing some welding at the moment on a car. It's not so much for saving money but to see if I can. Mental therapy in trying your hand.
Good luck VT!
What is the sander you have? What is that sanding tool called specifically? I think I might have something similar, but not sure. Super beginner here…
Thanks!!!
All of the stuff we have we got from Harbor Freight because it's less expensive and that's what we can afford. The first sander you see is called the Chicago Electric Power Tool Die Grinder BUT it is very hard to handle and I wouldn't try using it again. It was for me anyway. I wouldn't buy this one if you don't already have it. They probably have another sander that is more controllable. It's crazy strong and maybe I'm just not lol.
The rocker panel job was such a pain for me because of the gaping hole, but there are so many great suggestions in the comments section here, I highly recommend going through them and picking up a tip here and there.
I was a super beginner as well and that's why it doesn't look perfect at the end but anything you do will absolutely be better than how it started so keep that in mind!
You've got this!!
@@samechick Thanks so much! I’m tiny (5’1 after a good stretch 😂), so I would definitely prefer to have something smaller and a bit more manageable. Especially since I’ve never used anything like that before. Just looking to extend the life of our minivan a bit longer if possible. I appreciate your response!💜
If your going to fill with fiberglass put the fiberglass on wax paper let the wax paper hold it in place until it hardens.
Rubber gloves, mentioning foreshadowing for more gloves...and the the worry about ticks!
"And there's the thing I'm trying to hold so the door doesn't get paint on it...and the door did get paint on it."
Good job...!!!
Thank you Ivan!
La noi in Romania exista un adeziv numit Poxilina.
Cu el lipesc orice tabla de alta tabla.
V am zis acest lucru pentru ca am vazut ca v ati chinuit foarte mult sa astupati acea gaura.
Mi-a fost greu cu siguranță. După câțiva ani, din fericire, încă își face treaba.
The rubberized undercoating overtime cracks and traps water and makes it worse. I use either fluid film which is oil based or Rp342 which is wax based same for CRC HD works great too for a very long long time before having to reapply
Thanks for the tip!
@@samechick you’re welcome ❤️ glad to help. It took me forever to find the right stuff, the stuff listed above is marine grade protectant 🙂
Perhaps making spray foam molds of those sections will help doing the job easier.
Shes acc so funny
And pleasant to listen to 😊
Aww thank you!
Not allowed to repair cars in this in New Zealand. Has to be tig welded for safety
Blue Tape will pick up those paint drips to level...then you can just flash it again...😀
(After it dries a little...)
Seen another video guy used spray foam as a filler.. seemed to work great
Definitely would try that next time.
How has this repair held up one year later?
It has held up pretty well actually, there is new rust cropping up but it's not in a spot I "fixed." To be fair though we did have the running board re-attached, so maybe that's giving it some extra protection.
Hows this one holding up? Any bubbling?
No bubbling but some rust coming through in areas I didn't cover. Upstate NY and these rough winters make this sort of thing a never ending battle.
Gloves! Those purty hands gonna get beat up!
Next time!
There's great videos for DIY repair by Kurt's cottage. He shows a easy method to do it.
Wax paper and masking tape to hold the bondo and mesh up. Oh I see you found a ziplock for it.. lol
Hey :) how long hold it?
If you are asking if my repair has still held up, it has. There is a little rust showing up here and there but nothing like the "Before" picture. That's life here in upstate New York.
Even if it was still the fiber glass big chunk. Still way better than that rust 100 percent
Does any rust came since thoes fixes?
Hi Jakko_ok, I haven't had any rust return at all so far.
@@samechick super, I made it today also from chris video. I hope it will las for one year.ta least
@@JAKKO1997 Congratulations!
The question is: what does it look like after 2 years?
We put the running board back on after I was finished so I can't really see what it looks like at this point.
I had done some non-rocker panel related rust work on the other side and after a few years rust is starting to pop out in places, but such is life here in upstate NY. I will probably try to address that this year.
gonna try on my 2011 ford fusion! body shop ask for $1700 to fix . lol thanks!
You've got this! Don't be nervous like I was.
When you spray, spray like a robot. Maintain the same distance and speed with your spray can.
A simple and easy way to create something for the bondo to hold onto is to use a bottle of expanding foam. Spray some expanding foam into the rocker panel and once it expands, you can easily cut off the foam and shape it the way you like it. The foam makes a great backing for the bondo to hold onto once it expands and fills up the rocker panel. Makes working with large holes like this so much easier to work with. You did a great job, considering that bondo can be a pain to work with when it comes to large holes.
Yeah, really can't believe I didn't think of that here. It would have made this project easier, and it would have come out way better. Next time for sure I'll use this trick.
@@samechick please don't use expanding foam in this kind of repair. It traps moisture, and it will make the repair rust faster!
@@Evaldas65 Oh wow ok, thanks for letting us know!
@@samechick I used tin foil instead
HILLBILLY AUTO BODY SHOP , that should be the garage name youd make a killing , you have a HOLE & i have a rubber glove for it some kinda slogan like that lol ay atleast u got it done i woulda just payed to get it welded cause mannnnn gesussssss!
Honestly I just didn't have that kind of cash. If I did I probably would have purchased a vehicle with less rust =P Thanks for stopping by Eric!
@@samechick just joking around im glad u fixed the rocker it is definitely a improvement honestly, and your video is raw and also funny it helps ppl who never tryed this or that are scared to try and you just did it i like that keep it up ull get better n be able to weld yourself if you can do fiberglass n sanding u can learn to weld aswell, goodluck godbless hope for alot of success on the page 💯👍🏼🤘🏼
I do expandable foam first let it dry completely then razer blade it flat and one 2 thins coats of bondo and done
Oh man Chris, that is just the sort of advice I would have loved to have at the time. Brilliant. If I ever have to do this again, I'm definitely doing that. Thanks for the awesome tip.
Edit: My husband has to do some similar rust repair on his old Blazer soon. He's totally using the expandable foam idea. He can't believe we didn't think of it.
@@samechick yeah expanding foam is tesla level thinking. genius
Those panels are a critical part of the vehicle's safety / crash protection design - good luck in a front or side impact! This work would be illegal in the UK and you wouldn't be insured in the case of an accident. This is scary stuff!
Don't be afraid to fail while trying..
You are so right!
This is IMMORAL . STAY IN THE KITCHEN WHERE YOU BELONG!!!
After this I went in and made dinner for my husband! ❤
😳😯😳😯😳😯
Next time use expanding spray foam to fill those huge holes.
Expanding spray foam is a great way to collect moisture and rust them out again. I wouldn't go that route unless you don't plan on keeping the vehicle too long.
Next time try welding I bet you could do it just fine
You could of done it with plexiglass sheets :)
I will keep that in mind for next time! Thanks for the tip =) I really had no idea what I was doing 😆
You think the pros don't shove things like gloves or paper/cardboard up there?
LOL I really didn't think they did, but I guess it's a possibility!
Next time just put a big blob of fiberglass filler on a piece of wax paper and put in place and just keep pressing and holding it in place until it starts to go hard..
Thanks for that tip! Sounds a lot better than the torture I went through tbh. =)
Use foam gap filler next time
I mean. Um. It does look better after. 🙂
Rust is gone, the door shuts and the running board fits over it. It's a win for me.
Weld ,weld weld ,if you value your life. Thank god we have a yearly MOT here in the UK . Your car would be scrap in my country for bodging the repair.
Sa tiendra pas dans le temps sa va éclater car le mastic n est pas fait pour bourré une épaisseur en plus le temps que sa sèche intérieur elle a déjà bombé la peinture sa craquera
Il n'a pas encore craqué et je ne pouvais tout simplement pas me payer un atelier de carrosserie. Nous vivons assez modestement, si nous avions eu plus d'argent nous aurions probablement acheté une voiture en meilleur état. Merci d'avoir regardé.
Temporary fix! Will hold more water and continue to rust.
Definitely temporary but the best I could do. I checked for holes for water to get into and I didn't see any but it's true I could have missed some. Right now she's in the garage and out of winter's way. Thanks for watching =)
Why postings like this? Why discourage others this way?
Pool noodle
Next time!
Should have been welded there's no strength in that area anymore 😮😮
Actually it's covered by a side step that I believe is bolted to the frame so it's fine.
What is wrong with people? Who can possibly think this is ok? It’s a bloody mess!
Better than it was. And it was all I can afford.
I think She did an amazing job,and why not? It looks alot better than before and saved Herself a chunk of cash....also gave me inspiration,I'm gonna try it but with the blow foam and cardboard taped all around,poke some holes in it to spray it in,the cardboard holds it inside until it dries,saw another video on it about a year ago and been dying to try it,after this I feel inspired to try it!! 😁
@@LisaLisa-mx3hq people like Chris struggle very much with prospective. Not every car is a museum piece, most will never have any collector value. Some of us just want our work beater to look better. People like Chris also tend to have little experience, if they had any they’d share it. What people like Chris lack in experience they tend to make up for in emotion and confirmation bias.