Rust repair

[NC Tom]

I just noticed this today.

 

I have the same rusty spot of each side of the cab just behind the front fender wells. Is this a pro repair or can a layperson do it?

[rokinn]

I suspect that depends on the skill level of the lay person.  I suggest you pull the carpet and see how much damage actually is there.  

[NC Tom]

2 minutes ago, rokinn said:

I suspect that depends on the skill level of the lay person.  I suggest you pull the carpet and see how much damage actually is there.  

Yeah. Been meaning to do that.

[Smokeyyank]

Doable with the right tools and time. Plus its "unseen" so even if your welds look like Hellen Keller got to them no one will really see it. 

[89 MJ]

I concur with the other two said. 
 

There was a seam right there where the firewall overlapped the floor pans. More than likely, moisture got in there causing the rust you see. I would also bet that the rust is going to be much worse than you're seeing by the time that you pull the carpet up. When I got my truck, there was only a quarter sized hole visible from the bottom on the driver side. After pulling the vinyl floor covering, I needed the front half of the driver floor pan and a decently sized patch on the passenger side. That said, the trucks that had the vinyl floor covering instead of the carpet always seem to rust worse.

 

I think your best bet is to pull the carpet and then we will be able to come up with a better plan how to proceed. It might just be a minor patch that needs to be made, it might end up needing a full floor plan replacement where you'll need the floor braces too. Thankfully, Key Parts makes both the floor patches and the full floor pans for each side and it seems that the fit is excellent. 

 

I think the biggest question is, how confident are you with your cutting and welding skills? Floors are a pretty important thing to have and they're not always the most comfortable thing to weld in. If you can weld them in and make them strong, its probably something that you can tackle. If you haven't welded sheetmetal before, I would probably find someone who has done it before. 

[ktmall07]

When I did this repair, the passenger side had rusted through all the way back through and on both sides of the raised beam on top of the frame rails, so it was a ton of extra work to make a new one and try and salvage the seat mounts. Hopefully you don't have to do that! The front section closer to the firewall was not as difficult to reach or repair, especially if you're just cutting out a flat piece and seam welding. Just make sure to not weld in a straight line but tack weld in a clocklike pattern (similar to tightening lug nuts, so maybe start with corners, then ) so that you don't warp/melt through your new piece.

 

After welding new pieces in and grinding it relatively smooth, I covered everything in POR-15 and left if for a few days to really solidify so I wouldn't have the problem any more in the future. Obviously fixing leaks is the real way to prevent it from happening again, but while you have everything taken out you might as well to be extra sure!

[NC Tom]

On 4/5/2026 at 9:48 PM, 89 MJ said:

I think the biggest question is, how confident are you with your cutting and welding skills?

My what? Never done it. However, I'm really good tearing things apart. It's the reassembly that I struggle with.

[89 MJ]

10 hours ago, NC Tom said:

My what? Never done it. However, I'm really good tearing things apart. It's the reassembly that I struggle with.

Does it seem worthwhile to try to do it then? Especially if you’d need to buy the welder and the grinder. If you do want to do this. Practice on some extra sheetmetal first. I think I’d recommend bringing it to a pro. 

[hgeranium]

11 hours ago, NC Tom said:

My what? Never done it. However, I'm really good tearing things apart. It's the reassembly that I struggle with.

Never turn down the opportunity to learn! I'm in the same boat as you with many of these intermediate-to-advanced automotive things but if you have the time (and money) then why not throw your hat in the ring?

[Gojira94]

I did all my own cutting, grinding and prep. But since it’s been now more than 20 years since I did any welding I hired a friend of one of my kids that works for me at job #2. I paid him more than he asked - $325. Well worth it. He’s someone who welds every day, trained at the local community college. You could probably get hooked up with someone at your local CC. I agree this is a job for a professional, or at least a seasoned journeyman.

 

Start with pulling the carpet and seeing the extent of it. 

[NC Tom]

On 4/18/2026 at 11:46 PM, 89 MJ said:

Does it seem worthwhile to try to do it then? Especially if you’d need to buy the welder and the grinder. If you do want to do this. Practice on some extra sheetmetal first. I think I’d recommend bringing it to a pro. 

Sure. It would be good skill to have and use from time to time. Even if the welds are very pretty, they can be safe.

[NC Tom]

On 4/18/2026 at 11:52 PM, hgeranium said:

Never turn down the opportunity to learn! I'm in the same boat as you with many of these intermediate-to-advanced automotive things but if you have the time (and money) then why not throw your hat in the ring?

 

I agree and used tools can be an option. The bulk of my large woodworking tools are used.

[NC Tom]

On 4/19/2026 at 12:37 AM, Gojira94 said:

I did all my own cutting, grinding and prep. But since it’s been now more than 20 years since I did any welding I hired a friend of one of my kids that works for me at job #2. I paid him more than he asked - $325. Well worth it. He’s someone who welds every day, trained at the local community college. You could probably get hooked up with someone at your local CC. I agree this is a job for a professional, or at least a seasoned journeyman.

 

Start with pulling the carpet and seeing the extent of it. 

 

I do know some welders. I really don't want to pull the carpet. Ugh!

[89 MJ]

10 hours ago, NC Tom said:

Sure. It would be good skill to have and use from time to time. Even if the welds are very pretty, they can be safe.

 

10 hours ago, NC Tom said:

I really don't want to pull the carpet. Ugh!

How often do you use the truck? If it’s a truck that gets used often, take it somewhere to get it fixed. This thread was started 3 weeks ago and we haven’t even gotten to step one, pull the carpet. 

[ratrapp]

i can guarntee if its this bad from the bottom its worse in the inside.

[NC Tom]

53 minutes ago, 89 MJ said:

 

How often do you use the truck? If it’s a truck that gets used often, take it somewhere to get it fixed. This thread was started 3 weeks ago and we haven’t even gotten to step one, pull the carpet. 

I know. I work a lot of hours and I've turned my ankle, so I've been slow to get things done.