Clanceman 1995 Ram 2500 rust repair thread

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clanceman427

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Well, I knew this was in my future, and the PA state inspection confirmed it. My 1995 Dodge Ram 2500 SLT standard cab 8ft bed needs bodywork in order to pass. It needs:

-driver door replaced
-driver and passenger rocker panels replaced
-driver and passenger front cab mounts (the steel brackets spot welded to the floor and firewall) replaced

Here's a few pics of the areas that are bad:
 

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clanceman427

clanceman427

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I will document my progress on this thread. So far I have sourced all the parts needed, just need to get the welder going some more (and more, and more..:))

I was lucky enough to find my exact color combo door at a local salvage yard in great condition, an SLT door! So it has power everything and even a power mirror unlike mine. The rocker panels and cab mounts I found on Ebay.
 
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clanceman427

clanceman427

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Here is some progress removing the old driver's side rocker panel. the rust damage went from just under the front of the door, back to where the factory cab corner overlays the factory rocker. So I have cut the replacement rocker down to just the area needed to replace. I bought an awesome tool from Eastwood for removing factory spotwelds (since I'm terrible at free-hand drilling them :)) You can adjust the cutting depth with this tool and it's a much more controlled process. Pics seen below:
 

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Gr8bawana

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Since I don't live in a state that has those type if inspections I'm wondering how that has any effect on any safety issues the state might have. Big deal so it has some rust.
 
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clanceman427

clanceman427

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more pics. Of course, upon removing the factory rocker, I uncovered 2 rust holes that were about the size of a nickel but of course you have to cut back some to get to decent metal, so those had to be addressed. Then the last shows shows how I'm pre-drilling the spot weld holes in the new rocker panel with a drill press, truck in the background:
 

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clanceman427

clanceman427

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Since I don't live in a state that has those type if inspections I'm wondering how that has any effect on any safety issues the state might have. Big deal so it has some rust.

I know. The way it was explained to me was (and before I took it for inspection, I took a roll of aluminum HVAC tape and covered up all the rust holes in the door, rockers, and fenders and bed). They said that while the tape job looked nice, it forms no barrier for items that might get kicked up from the road like a stick or some other item. So from a safety perspective, OK I can see that. They also tried to say that fumes are getting into the passenger compartment, however, to which I always say, "yeah, and I could be in bumper-to-bumper traffic in the middle of the summer with my windows rolled down, inhaling 6 other cars' fumes, from their tailpipes, what's the difference?hehe :) The cab mounts I can see as a safety thing. I just don't buy the fumes argument.
 
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clanceman427

clanceman427

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Checking in with some progress. Got the replacement rocker trimmed, drilled for plug welds, and welded in the replacement rocker, it's about 75% welded. All the top side plug welds are done, and the edge seams are mostly done. Then the bottom plug welds will be last. Then some Metal-to-Metal filler, sand, seam seal, prime, and paint.
 
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