Found rust on my supposed rust free 89 sierra

[Kens1990K2500]

Yeah, and that's why I didn't use bondo. I cut metal plugs to fill the 3 holes I had. I welded the plugs in, ( no pics of that) grinded down the welds. Then my coworker ( the other welder) who has done a bunch of MC repairs, said, He used some JB Weld with metal in it, as body filler. Well I don't care about the metal in the JB weld, I am not concerned about the repair pulling a magnet, ( that's why he said the one with metal in it) but I also know how strong JB weld is, and it wont fall out, so that's what I used. It sands good and blends well. The repair came out good, I still need to paint blend sand it but its almost perfect. In doing this repair, I couldn't under stand why the cab corner rusted out. It rusted from the inside out. The drain vents were not blocked, and I am meticulous about cleaning my truck so ***. After cutting out the rust, the 3 holes were big enough to see in there. There is some insulation in the cab corner at the top, rite where mine rusted out. This has to be holding condensate water. There is no leak there. I also rust inhibitor treated everything inside before repairing. I will redo or recoat the inside of the cab corner, in the near future.

Looks good. This job is in my truck's future

 

[Tractor joe]

Well got the old stuff.cut out and panel bonded the new one in.. going to let the panel bond cure till tomorrow afternoon then zap in some spot welds on the door jam and cut a peice to fill some of the void and weld it on.. welding the part between the cab and bed will be tough.. will use some body filler back there unfortunately..

I dont understand why someone put bondo on the cab between the bed and cab...right over paint.. makes me worry about what's underneath it all... time will tell.

I did paint the inside of the cab corner with rustolium after lightly sanding it and cleaning it up and sprayed weld able primer on the metal that's going to be welded

 

[Tractor joe]

One more picture

 

[Tractor joe]

Tacked in the driver side corner.. the rest is getting bondo.. keep burning through the metal on my lowest setting.. not to bad after grinding it down

 

[98chevy2500SS]

It's always fun finding all the bondo isn't it? Lol, jokes aside, my 97 was the same way. Looked decent from afar, but once it started rusting more, the bondo was just falling apart (fell apart in big chunks on the rockers!).

Some people (like the PO) need to realize you are NOT supposed to lay a thick layer of bondo over rusty metal.

 

[Raspi454]

Old owner said no rust.. the floor underneath looks mint.. I noticed some very slight bubbles on the cab corner on the passenger side and poked it with a flathead.. went right through! About a quarter size.. metal inside looks really good though..

Driver side.. ha... lots of bondo! Gurr.. stupid @$$ could of easily fixed this but let someone go bondo crazy and made it worse.. ordered some cab corners.. should be a easy, just time consuming fix.. I have ALOT of experience fixing rust from the 50s and 60s caddys I've had over the years.. spent alot of time making peices and welding them on.. use as little filler as possible

is it ok to use filler on small dents, like quarter sized?
edit: I'm not a whole lot knowledgeable on body work

 

[Tractor joe]

Pretty much done with the driver side.. under rhe cab pictures.. the gray stuff is the panel bond I used.. looks really clean underneath

 

[Tractor joe]

Painted.. closest color that matches.. need to to to home depot etc and get some spray paint mixed up to match

 

[TonyM]

Looks good, I cant beleive how clean the metal is on the inside. On a side note, there is nothing wrong with bondo/plastic filler if done right. When I was in autobody school, the instructor mixed up some filler and glued 2 pieces of sheetmetal together. After it cured he put it in the vice and beat it with a hammer every which way until the metal finally tore from fatigue and the filler was unscathed and holding.

 

[Tractor joe]

Other side.. I cut out a 2x2 peice to insure all the bad stuff was gone...saw a little corrosion starting inside and cleaned it the best I could and hosed it down with the weld able zinc primer that is made for adhering to galvanized metal.. should last another 10 years hopefully