Josue's Collision Repair Thread.

[Sparky]

Do you do just collision repair, or other types like rust repairs? I'm guessing they are two different kinds of animals.

 

[JosueLT]

It is, but it isn't. It's all a part of restoring/rebuilding/refinishing a vehicle to make it look brand new again, and that's what my job description would be.

Rust is just a total nightmare to deal with, mainly because it's so hard to completely get rid of and they don't pay us nearly enough to fix it. And to top it off, there isn't supposed to be any kind of warranty on rust repairs because of this (we usually warranty our repairs for the life of the car), but for some stupid reason, there have been a few rust jobs that we've had to re-do because it was rusting again.

Here's a F-150 that I had to fix back in the summer, from a thread I made on my Mazda forum. A lot of their cars are rusty, so they were inquiring as well. lol

The vehicle is a Ford F-150 Crew Cab. For some reason, the guy must love the truck enough to put over $2400 in TRYING to fix his rust. (I'll explain the "trying" part in a bit) And they need to call him back and hit him up for more money because the rust was FAR worse than they thought....idiots.

BIG HONKING hole in the rocker. I've got to replace it all together...

Towards the back of the driver side rocker...I chipped it away, and there's a hole there.

The bottoms of the doors are just awefull. The thing NEEDS new doors, but they're bent on me patching good metal in like it's going to stop the rotting. There are 3 doors that are this bad, and the other one isn't because it got replaced not too long ago.

Tools of choice. Cut off wheel, target grinder, and wire wheel. The wire wheel is a great tool for this job, it really gets in the metal and digs out all the crap. Not as good as sandblasting, but on something THIS bad, sandblasting won't do shit anyway.

This is the reason why you'll never stop rust like this...even though I'm replacing the outer rocker, the inner rocker looks like this (the whole underside of the cab actually), and there's no way to ever get inside all the nooks, crannies, creases, between panels, etc, to remove the rust. It's not a matter of if it rusts again, but when...

Same thing after I cleaned out the door jams. I may have removed the crap on the outside, but there's still rust on the inside in between the panels. Their bright idea is for me to cut the bottom of the door off, that way I can get inside the panel and clean all that out, then weld a patch in. I'll show you what I'm talking about when I get the patch panels in.

This is the passanger side cab corner. They didn't think it was bad....but again, idiots...

This is the only GOOD door on the truck. All I needed to do was clean the surface rust off...feather the paint out...

Mask off a nice line, so I'm not just spreading around seam sealer all willy nilly! (grey stuff is metal etch primer)

And Voila!

Seam sealer...

This is what all the doors will look like. The seam sealer will slow down the rust, but again, it's not going to stop it...

That's all for now, more to follow so keep stopping by!

 

[JosueLT]

More...

Updates!

WHY ALL THIS RUST WILL BE BACK!!! You just can't get behind/inside/around all the panels...

I wasn't going to use the whole rocker section, but after trying to clean up this part of the original rocker, it turned into a big hole...so I had to remove the fender to install the whole thing.

Lil extend-a-patch...

I wound up gluing the majority of the rocker on. I didn't want to gut half the interior to pull the carpet back enough to use the resistance spot welder, plus I wouldn't have gotten paid for that! It's bad enough I didn't get paid to take the doors off, which took me over an hour because Ford sucks and doesn't like to use plugs for the wiring harness.

And the door bottoms came in today. Not really what I expected, but they'll work. I was expecting just a flat sheet of metal with a little fold on the bottom, not half a door skin.

 

[JosueLT]

More....

Not too much today, just made a patch for the passanger cab corner and welded it in.

Came out freaking sweet if I don't say so myself! haha

You can see the curves and bends in the piece...

Used this. It's filled with buckshot beads....kind of some Jesse James pound out a gas tank type stuff. lol

 

[JosueLT]

More...

Been busy getting the car going every night lately, but here are some updates that happened in the middle of last week.

Finished off the rockers/cab corner

Door repair. You can see how bad the shell is once this section of skin is off.

All welded in. Warped the SHIT out of the door, but I just beat in the high spots and bondoed it end to end. Came out nice...plus it gets rocker guard as well.

Door skin folded over the shell...

Bondoed...

The truck and doors are painted now, and I'll be putting it together tomorrow or tuesday. Finished pics to come!

 

[JosueLT]

Done...

This repair should last at least a year or more. Rust comes back, but it's not exactly an overnight process.

Here are the finished pics...

I'm DOUCHING my car with this stuff before winter hits...lol

Inside the doors...

 

[07ChevyTruck]

Both trucks look good.

But the ford had rust.

 

[Ghoster]

wow.... with that much rust it seems like a waste of time to fix it! Makes me wonder if the owner was putting minimum $$$$ in to get the rust hidden so he could get maximum $$$$ on a sale.

 

[HARDTRAILZ]

I bet my doors are not much better in the rust department. As an 06 it has a disgusting amount of rust showing at the bottom inside of the doors. I bet most people dont realize how much rust they have they can not see.

 

[Ghoster]

I bet my doors are not much better in the rust department. As an 06 it has a disgusting amount of rust showing at the bottom inside of the doors. I bet most people dont realize how much rust they have they can not see.

I spend an inordinately large amount of time checking for rust on my doors and making sure the holes are all clear so they can drain properly. I had to have a door swapped out on my Sierra years ago because of the rust. It was all on the inside. I didn't know it had a problem until the bottom edge of the door started falling off. I think the paint was holding it all together.

 

[Sparky]

Yeah, my doors look like those

 

[07ChevyTruck]

Yeah, my doors look like those

That ain't good. That ain't good at all.

 

[Sparky]

That ain't good. That ain't good at all.

I have a quote of $2000 to repair all 4 doors (basically going to cut the entire lower part of the door off), both rear wheel wells, a few misc spots here and there, and the lower part of my tailgate. However, given its condition, I suspect I'll just get a rust-free tailgate instead and have him fill the seams (where most of the rust starts) and put a good layer of rustproofing on the inside of the gate. Should buy me a few years if done right. I plan on taking a wire brush (or wire wheel on a drill), cleaning up the frame, and coating it in POR-15 along with doing what I can to the underbody like the floorpans and such before those rust. Basically have the pro do the stuff you actually see, and the other stuff that doesn't matter I'll do myself.

 

[JosueLT]

wow.... with that much rust it seems like a waste of time to fix it! Makes me wonder if the owner was putting minimum $$$$ in to get the rust hidden so he could get maximum $$$$ on a sale.

It WAS a waste of time! LOL I think he just had a nice (the rest of the truck was well maintained) paid off truck that he didn't want to get rid of, but wanted to make it look a little better for a few more years. I'm just not sure I would have spent $3500 for that. haha Rust that bad isn't an overnight process though, so it should last a little while, hopefully making the money spent worth it to him.

I bet my doors are not much better in the rust department. As an 06 it has a disgusting amount of rust showing at the bottom inside of the doors. I bet most people dont realize how much rust they have they can not see.

Exactly. That's what the biggest appeal of my DD is. All the Protege5's in the area are already rusting, bad, have had the rust repaired (I can always tell, bodyman's eye lol) or appear clean, but you know all the seams and underneath the car are rusting. I bought mine from TN though, so I KNOW it's clean! Not fresh off the factory line clean....but clean like it's only 2 years old or something.

Before winter hit, I undercoated and rustproofed the SHIT out of it too, trying to prolong the seemingly inevitable when you have to deal with snow and salt.

They always rust out by the strut towers.

No pics, but I also took the interior panels off and sprayed inside the doors, quarter panels, and hatch....a LOT. lol

I have a quote of $2000 to repair all 4 doors (basically going to cut the entire lower part of the door off), both rear wheel wells, a few misc spots here and there, and the lower part of my tailgate. However, given its condition, I suspect I'll just get a rust-free tailgate instead and have him fill the seams (where most of the rust starts) and put a good layer of rustproofing on the inside of the gate. Should buy me a few years if done right. I plan on taking a wire brush (or wire wheel on a drill), cleaning up the frame, and coating it in POR-15 along with doing what I can to the underbody like the floorpans and such before those rust. Basically have the pro do the stuff you actually see, and the other stuff that doesn't matter I'll do myself.

Sounds like a good plan! That's what I'm doing to a friends '89 Toyota truck in my garage. I'll have to transfer pics of that job too.

 

[HARDTRAILZ]

I need to come visit you and have you help me coat mine. Looks better than the $.99 spraypaint and mud I use... Well Done!

 

[JosueLT]

Haha, thanks!

Just gotta know what to use. The amber inner panel rustproofing is nice because it seeps and runs into all the places paint coverage can't be reached. And the black stuff is just regular rubberized undercoating. There might be some better stuff out there, but this is only $5 a can, and as long as all the seams are coated well, it should be enough.

 

[07ChevyTruck]

I have a quote of $2000 to repair all 4 doors (basically going to cut the entire lower part of the door off), both rear wheel wells, a few misc spots here and there, and the lower part of my tailgate. However, given its condition, I suspect I'll just get a rust-free tailgate instead and have him fill the seams (where most of the rust starts) and put a good layer of rustproofing on the inside of the gate. Should buy me a few years if done right. I plan on taking a wire brush (or wire wheel on a drill), cleaning up the frame, and coating it in POR-15 along with doing what I can to the underbody like the floorpans and such before those rust. Basically have the pro do the stuff you actually see, and the other stuff that doesn't matter I'll do myself.

I agree with JosueLT it is a good plan.

JosueLT - Keep the photos coming.

 

[JosueLT]

Some have seen these in the Bedliner thread, but here are the pics of the Toyota I'm doing at home.

I always wondered how they shipped items like fenders. Apparently they come in boxes that look like the goodies inside!

How the box is secured

Rockin out with the new Fender!

Test fitting the new fender

New tailgate

Glass out

Omg, heat is the best thing ever!

It kind of messes up the paint a little bit

Other side of the heated area

Old tailgate

We eated our Wheaties and took the bed off by ourselves!

All nakie!

Not a whole lot left

Hood stripped and bondo on a big dent

Josh stripped the old bondo from a previous repair and put new in its place

New patch welded in a rotten hole behind the rear driver side

Grinding down the welds

Always srs bsns

Cleaned up

The old rubberized frame protectant did a good job in some areas. I stripped it all with a wire wheel, and the black paint still looks like new. In other areas, not so much, but it all seems to be very solid

Yep, the floor isn't textured, that's all junk I wire wheeled off

Frame de-scaled

Grade A patch work. The old tab rusted out, and if the patch had a hole in it, you'd never know which one was the one that was replaced.

Sanding down the bondo on the rear passenger corner

Just like Dexter's kill room

All ready for primer

It got dark, we worked about 10 hours on it.. It looks so tiny with all of the parts off of it!

Full house! (or cave, obviously the stock flash wasn't cutting it and I didn't bring my external)

 

[JosueLT]

......

Got a bit of work done tonight

Josh got the antenna hole shaved the other day. We'll treat the backside against rust before it goes back on the truck.

Cab sanded down, still waiting on the stupid glass guy to show up to take the windshield out

Roof of the cab stripped, ready for primer

Awww yeah, looks brand new. These are the lids on the gas tank

It's the lower metal hardline that's leaking. I don't think we'll be able to get the screws out, and obviously the use of heat isn't really recommended. Might just have to get a whole new tank

Bed shot in primer, getting ready to sand out the orange peel

Shit sucks, that's 113$ worth of supplies…

The paint looks awesome on the inside of the door where it was never exposed. I bet this truck looked awesome like 20 years ago…

Part of the passenger side rocker Josh pulled out with the stud gun.

Sweet portable work light Josh made the other day, I think I'll definitely be copying the idea. It's perfect for a garage where the lighting isn't ideal, and should last a lot longer than those little work lights that seem to have about an hour of bulb life.

Hard to see the light it puts out, but maybe you can tell

 

[JosueLT]

.....

Well guys, you know me, so I won't lie, I've been lazy with the updates. I'll try to win you back with a video, though. I probably wouldn't watch it at work, or if your lady (or man, I don't judge) gets offended with sexytime stuff. (naughty)
Alex Gaudino feat Crystal Waters - Destination Calabria (HD) - YouTube

Last time I left off, we were waiting for the glass guy to come take the windshield out. He kept dicking Josh around, but another dude finally came and got it done.

Josh, prepping the surface

Yeah.. not looking so good. The windshield was replaced at one point, and the guy who did it obviously scratched the metal while scraping the old urethane off. He didn't bother to cover the raw metal (probably a case of, "you only paid to have the windshield replaced, not to have it done right"), as clearly that's not his problem, so rust and time had their way with the window surround.

Not good either (passenger side)

At least the top and bottom were in good shape.

That left us waiting to get some new A pillars off a truck from the junkyard. It ended up being the same one I got the door from. The guys were helpful, and quoted me for just the pillars. I asked how much for the dash, and it was going to be another 100$, so I said forget it.

I went to the yard to pick up the pillars in the 626. I figured they would be cut out and ready to go. The guy's like "so you got a truck to load this in?" and I'm like, "A trunk?" being optimistic, lol. He showed me what they did.

It was going to take too long for him to hack through the dash, so he just whacked out the whole firewall and gave that to me for the quoted price. I ended up getting the dash and a lot of other goodies too! I love good surprises, even though it wouldn't fit in my car!

Nothin but serious business here with the Mazda crew

Some surface rust on the new door ground down and coated with a product that chemically converts the rust into an inert form.

Drying it with the heat gun that can do 1200*F

Old A pillars, all cut out

The insides and structure inside are coated with some kind of awesome battleship paint that seems to be pretty robust and good for resisting rust. I'm really surprised they didn't look much worse than this. Usually the insides are 10x worse than the surface.

Only the structural part of the pillar was left on, Josh cut the skins off.

Lots of layers

Bottom of the driver's side

Bottom of the passenger's side

Top passenger's side

Fender, ready to be sanded

Door, awaiting seam sealer

Josh's skillful finger at the ready

Beauty

Whups

 

[JosueLT]

Here are some of the LT I'm doing this week. I did this yesterday, but our power went out for over 8 hours, so I couldn't update. lol It's painted now, and will be going back together tomorrow.

Grinding all 4 sides to use the spot welder.

Mocked up.

The welder. This is an older version that didn't get used much, so they brought it up for us to use. We have a better one down in the main shop. (There are 2 buildings to our shop) They're pretty nice to have though! Much MUCH easier than mig welding everything together, plus they have different attachments...one does single sided welds, for when you can't get behind the panel to have all 4 sides cleaned, and another is a dent puller. It welds to the panel, then has a slide hammer connected to it so you can quickly pull the dent out and go to the next low spot.

 

[JosueLT]

Dent repair pics...


We use a stud welder on dents most of the time. It's actually kind of rare to be able to get behind a panel and pry/beat a dent out. The welder welds studs to the panel...in the low spots obviously.

Then you attach the puller and beat/pull the low spots out.

You can't see this panel too well, but it was pretty bad.

After pulling the dents out...

Mud...

Dangerous stuff people, protect yourself!

Door on a stand (easier to sand), with finishing glaze applied. It fills in all the imperfections left behind in the bondo.

Done. (I put a new skin on the front door. I have pics of that too if you guys are curious. )

Another dent repaired...

Heavier repair...

When clamped together, the studs are usually pretty strong, nice for getting panels to line up.

 

[mapanch]

Done. (I put a new skin on the front door. I have pics of that too if you guys are curious. )

Of course we are curious. You should know us better than that . . .

 

[JosueLT]

Haha....touche!

After gutting the door, I decide where to section the skin. It's the same thing as the quarter panels. Sometimes I'll put the entire skin on, and not have to section anything, but it's really 6 of one, half dozen of the other...they both take about the same time.

This is how you get the skin off. A grinder on the edge until it separates...

Then a tool to break the seam...

New skin...

Sleeve again...

Door skin adhesive. Goes around the edge to glue the skin on.

This is where the skill sets in. lol A dolley on the edge....

And a door skin hammer to roll the edge over...all the way around! Forearms really take a beating, from all the smaller hammer strokes. It's a finesse game so you don't damage the outside of the skin.

After that, I usually take a grinder around the outside edge, just to get rid of the little waves left behind. That's why in the finished bondo pic up there, the perimeter of the door is bare metal.

Same on that Malibu Maxx...

 

[Sparky]

That is amazing work.

Maybe I should drive by your place sometime and see what kind of recommendations and/or quote you'd give me for my repairs That is, if you're interested at all.

Yes, I had an ulterior motive when I asked about rust repair, but I'm sure you suspected that!

 

[JosueLT]

No worries!

I can check it out for you next time we're at a meet or something and give you my opinion. I think the distance would make the repair process more of a pain than it'd be worth if I were to do it myself.

 

[Boricua SS]

so, did that guy ever come and get the truck out so you can have your garage spot back

 

[JosueLT]

Yup! We got it out on NYE. Now he just needs to get it to the painter, and back to me so I can put it back together and get my monies!

 

[Boricua SS]

Noooice... should make for a nice addition to your tax refund

 

[JosueLT]

IF he gets it done in the near future! My guess is, with how much he procrastinated when the truck was here taking up my garage spot, it will take him twice as long to get it down to the painter. The truck is sitting at his deceased grandmother's house, so it's definitely out of sight, out of mind now. He even said once it's put together, he's not going to drive it until the spring, when we have a chance to finish coating the frame and spray the bedliner on, so that leads me to believe he's going to wait until then to get it painted.

 

[07ChevyTruck]

After seing all these pic. If I lived out your way Josh and I need some work done. You would get the job for sure.

 

[JosueLT]

Thanks! I'd do an awesome job too!!

You just gotta take pride in your work, no matter what it is. I've been busting ass for years, even back when I was cleaning cars and sweeping floors. Those were the cleanest cars and floors I could make them! Truth be told though, I hate my job nowadays....it's a real bullshit way to make a living. Insurance companies telling you how much they're going to pay you to do something, shop owners screwing you out of money, junk aftermarket and used parts, not knowing how much I'm getting paid at the end of the week....it's tough! I love being able to fix cars like this, but I just don't want to do it for the next 30 years.

Still though, I take pride in every job I do, and do the best job I can. None of the above is the customers' fault, so they shouldn't get an inferior repair from some disgruntled tech.

 

[djthumper]

Thanks! I'd do an awesome job too!!

You just gotta take pride in your work, no matter what it is. I've been busting ass for years, even back when I was cleaning cars and sweeping floors. Those were the cleanest cars and floors I could make them! Truth be told though, I hate my job nowadays....it's a real bullshit way to make a living. Insurance companies telling you how much they're going to pay you to do something, shop owners screwing you out of money, junk aftermarket and used parts, not knowing how much I'm getting paid at the end of the week....it's tough! I love being able to fix cars like this, but I just don't want to do it for the next 30 years.

Still though, I take pride in every job I do, and do the best job I can. None of the above is the customers' fault, so they shouldn't get an inferior repair from some disgruntled tech.

I agree with you on the BS. I am glad I got out when I did. Granted I did it for the military and did a lot of side work. When I looked at doing it again after getting out it was not worth the hassle.

 

[JosueLT]

I wish I could get out. I have a degree in Air Traffic Control, and graduated almost 3 years ago, but the FAA's hiring process is a complete joke, and I'm not sure when or even IF I'll get hired.

I can't go back to school and add to my degree, i wouldn't be able to afford it. I make too much money to get any help financially too. Plus, we have a baby on the way, so our plans are REALLY going to be put on the back burner now!

 

[HARDTRAILZ]

I wish I could get out. I have a degree in Air Traffic Control, and graduated almost 3 years ago, but the FAA's hiring process is a complete joke, and I'm not sure when or even IF I'll get hired.

I can't go back to school and add to my degree, i wouldn't be able to afford it. I make too much money to get any help financially too. Plus, we have a baby on the way, so our plans are REALLY going to be put on the back burner now!

My neighbor/drinking buddy is an air traffic controller here in Indy. Not sure if he could help, but maybe... I will ask if he has any tips for getting on or contacts that may help you.

Honestly, my daughter costs way less than what people made it out to be. It is up to you what you spend really. We use cloth diapers and for under 500 have all the diaper for a couple kids. Moms can produce the bulk of the food. Clothes are outgrown so fast that garage sales/family/consignment shops are the way to go.

 

[07ChevyTruck]

Thanks! I'd do an awesome job too!!

You just gotta take pride in your work, no matter what it is. I've been busting ass for years, even back when I was cleaning cars and sweeping floors. Those were the cleanest cars and floors I could make them! Truth be told though, I hate my job nowadays....it's a real bullshit way to make a living. Insurance companies telling you how much they're going to pay you to do something, shop owners screwing you out of money, junk aftermarket and used parts, not knowing how much I'm getting paid at the end of the week....it's tough! I love being able to fix cars like this, but I just don't want to do it for the next 30 years.

Still though, I take pride in every job I do, and do the best job I can. None of the above is the customers' fault, so they shouldn't get an inferior repair from some disgruntled tech.

My friend who repaired my 04 after it was hit says the same thing when it comes to those damn insurance companies. Quick as anything to take your money, but slow as you know what to pay out.

 

[djthumper]

I wish I could get out. I have a degree in Air Traffic Control, and graduated almost 3 years ago, but the FAA's hiring process is a complete joke, and I'm not sure when or even IF I'll get hired.

I can't go back to school and add to my degree, i wouldn't be able to afford it. I make too much money to get any help financially too. Plus, we have a baby on the way, so our plans are REALLY going to be put on the back burner now!

Now that really sucks to get the degree required for the job and not able to get a job in the field. I can definitely relate, I was a medic/EMT after being a allied tradesman, when I got out I could not get a job in the medical field to save my life. And the making too much money when you are just getting by is bad too.

 

[mapanch]

Now that really sucks to get the degree required for the job and not able to get a job in the field. I can definitely relate, I was a medic/EMT after being a allied tradesman, when I got out I could not get a job in the medical field to save my life. And the making too much money when you are just getting by is bad too.

I'm in the same boat. Have a degree in Health Care Admin but I'm working at Kroger still. Graduated Dec 2010. Can't find anything, and I make pretty decent money, and my insurance is awesome and dirt cheap. Oh well . . .. .

 

[JosueLT]

Shitty part is, I can't really do anything else with the degree, but add to it. Or maybe it'd help me get some random meaningless job where they're just looking for someone with a piece of paper. (it's actually an Associate Degree in Applied Science) But, a job like that would probably only pay half of what I make now.

I'll just have to keep hoping for the best and take each day as it comes I guess!

My neighbor/drinking buddy is an air traffic controller here in Indy. Not sure if he could help, but maybe... I will ask if he has any tips for getting on or contacts that may help you.

Honestly, my daughter costs way less than what people made it out to be. It is up to you what you spend really. We use cloth diapers and for under 500 have all the diaper for a couple kids. Moms can produce the bulk of the food. Clothes are outgrown so fast that garage sales/family/consignment shops are the way to go.

My mother has 24 years in as a controller. I've made a bunch of contacts, including a few that do the hiring, but it hasn't panned out yet.

And I'm less worried about the day to day stuff with the baby. I'm more concerned with the drop in income while the wife takes 12 wks of maternity leave, then the astronomical costs of day care once she goes back to work! Insurance going up too...we're barely going to be able to keep our heads above water. That's why I hate this business so much, I'm constantly worried about having enough work to make a good paycheck. The holidays are always a slow time, plus our shop is in a transitional period with a few guys coming and going, and new methods of doing things. My paychecks have been 30-40% less than when we're busy and doing "good". When it's good, it's GOOD...when it's bad, it's freakin BAD! lol If my checks drop like this with the baby here, we won't be able to survive.

My friend who repaired my 04 after it was hit says the same thing when it comes to those damn insurance companies. Quick as anything to take your money, but slow as you know what to pay out.

I'm tellin ya...it's terrible! You pay all this money for insurance, then when it comes time to actually USE it, the insurance company cuts corners left and right to save themselves money on the repair. They write the absolute cheapest estimate they can, using junk aftermarket and used parts, repairing parts that need replaced, not paying to blend colors, it goes on and on. All in all...definitely NOT repairing your car to "pre-accident" condition.

 

[JosueLT]

And I put the LT together today. Bumper gave me some crap trying to get the gap closed up to the fender. It was an OEM bumper, but it came from a GM Outlet store and was sold "as-is", meaning it had defects in it and was kicked off the assembly line. The new left headlight was aftermarket, and if any of you have pulled your headlights out, you know those clips that are almost underneath the fender can be a bitch! This one fit pretty nice though.

Still has the normal ripples on top...lol