Bondo for wheel arch panel

[Abather Almajedi]

Hello. I have 2004 Dodge ram 1500 with 5.7L.
It have rust on rear wheel arch panel. I have some questions about Bondo. I read a lot of reviews and most of them said the rust will come back in short time after patched a new Bondo. What should I do? What is the best way to do it?

Thanks

 

[SYKRAMMAN]

Cut out the rust, weld in new panel. The only true way to fix it, or you’ll be doing the bondo and paint process over n over in short time.

 

[Abather Almajedi]

Oh what kind of Bondo should I get? I noticed they have different Bondo. Like.... Fiberglass. Filler. Go on.

 

[likes2build]

Cut out the rust, weld in new panel. The only true way to fix it, or you’ll be doing the bondo and paint process over n over in short time.

Plastic body filler is like a sponge and absorbs water, fiberglass reinforced filler is a little better but you'll end up doing it again and again. The only long lasting repair is metal and you need to go well beyond the damaged outer area and patch any inner perforated areas as well.

 

[SYKRAMMAN]

Oh what kind of Bondo should I get? I noticed they have different Bondo. Like.... Fiberglass. Filler. Go on.

View attachment 140545

Umm that’s not going to work out well with it being that far gone.

 

[Abather Almajedi]

Hmm... The best way to cut the metal then put rust converter interior panel before welding the new metal. Right?

 

[likes2build]

Oh what kind of Bondo should I get? I noticed they have different Bondo. Like.... Fiberglass. Filler. Go on.

View attachment 140545

Just saw your picture and I'll be honest the way it's bubbled up to the filler door I wouldn't be surprised if someone was there before. You are really going to need a boxside and an inner wheelhouse. If the other side has any problems you would be dollars ahead to replace the complete box assembly with a rust free one.

 

[SYKRAMMAN]

Just saw your picture and I'll be honest the way it's bubbled up to the filler door I wouldn't be surprised if someone was there before. You are really going to need a boxside and an inner wheelhouse. If the other side has any problems you would be dollars ahead to replace the complete box assembly with a rust free one.

Definitely.

 

[Abather Almajedi]

Definitely.

What about this another side?

 

[SYKRAMMAN]

What about this another side?

View attachment 140547

What likestobuild said, it will be better to just replace the whole box. You can find rust free used ones for about a grand or so, depending on area.

 

[Abather Almajedi]

What likestobuild said, it will be better to just replace the whole box. You can find rust free used ones for about a grand or so, depending on area.

Let me find the whole box and see what they have.

 

[SYKRAMMAN]

Let me find the whole box and see what they have.

I saw on Craigslist in upstate ny, a guy has a ****load of rust free boxes for several different makes/models.

 

[Abather Almajedi]

I'm curious for a while. My ram have 6.5 ft bed. My question is can I put 8 ft bed on my ram? If not, why?

 

[SYKRAMMAN]

I'm curious for a while. My ram have 6.5 ft bed. My question is can I put 8 ft bed on my ram? If not, why?

No because of wheel base.

 

[gofishn]

Cut out the rust, weld in new panel. The only true way to fix it, or you’ll be doing the bondo and paint process over n over in short time.

and be aware that even then, you could be seeing rust, at your panel welds, in slightly longer time than but bondo but less 6-8 years.

 

[gofishn]

Just saw your picture and I'll be honest the way it's bubbled up to the filler door I wouldn't be surprised if someone was there before. You are really going to need a boxside and an inner wheelhouse. If the other side has any problems you would be dollars ahead to replace the complete box assembly with a rust free one.

Much easier too./

 

[Abather Almajedi]

All right. Last question... Let's say I replace the whole bed, then what? I mean what should I put a protection under wheel arch to prevent the rust in future? I know I will have to clean the wheel arch everyday during winter in Michigan.
Make sense?

 

[SYKRAMMAN]

All right. Last question... Let's say I replace the whole bed, then what? I mean what should I put a protection under wheel arch to prevent the rust in future? I know I will have to clean the wheel arch everyday during winter in Michigan.
Make sense?

You can have it under coated or what I do is I fluid film twice a year keeps that cancer away. Takes about 6 cans each time.

 

[Abather Almajedi]

You can have it under coated or what I do is I fluid film twice a year keeps that cancer away. Takes about 6 cans each time.

Wow amazing!

 

[likes2build]

All right. Last question... Let's say I replace the whole bed, then what? I mean what should I put a protection under wheel arch to prevent the rust in future? I know I will have to clean the wheel arch everyday during winter in Michigan.
Make sense?

The truth is that the foam caulk that you see between the inner wheelhouse and the outer panel is the problem from the day they build them. It acts like a sponge and stays wet unless you're in a really dry climate. Add the stake pockets, the drain / flush holes on the inner, throw in road salt and dirt and you have the killer combination for rust. You need to flush the area between the 2 panels when you buy a good box and then try to seal every opening that lets the crud in after it dries. I've repaired rust all my life and the only guarantee a customer ever gets unfortunately is that it's going to come back. The better the job you do and the more metal you replace is the only thing that buys you more time in-between. Find a rust free southwestern box and you'll be safe and happy for a long time.