Poor Man's Body Repair Part 1

I have to do major body work on our 1990 Ford Econoline, I can't afford to have it done at a body shop.
Plus it would cost more than the van is worth, so being a jack-ass of all trades and a master of none, I have to do the job myself.
I have been doing body work for years on all the old cars I have owned in the past.
I use galv. sheet metal and pop rivits and rusty metal primer.
This video is MY WAY, the poor man's way of fixing the body rot, it has to be done, the van runs good but the body is going to hell.
Soooo...If any of you that ARE in the body shop business and want to be critic, please don't, I do not have a garage or the equipment to do it the RIGHT way.
To do it the right way would tie up the van for weeks, we drive the van almost every day.
This video is for you do-it-yourselfer's out there.
Thanks.

Category:

Autos & Vehicles

Tags:

• Auto
• Body
• Repair
• Pop-Rivits
• Sheet
• Metal
• Tin-Snips
• Rust
• Rot
• 1990
• Ford
• Econoline
• Rear
• Quarter
• Panel

[SmoothDonkey]

Try a manual nut splitter on the bumper bolts. It will just split the nut and not damage your bumper bolt. They are not expensive, and saves the bolts. Or just grind a few slots on either side of the nut and hammer it off. Thus preserving the carriage bolt. Just don't cut too deep and hit the threads. Also, you should be able to get chrome carriage bolts from most hardware stores. Just makes sure its the right grade. A google search shows lots. I work in a body shop and that's what it do.

[old64goat]

@SmoothDonkey I can not get chrome carriage bolts no where I tried.

But the problem is you can NOT even get in there, there is NO romm to even get a socket on the nut, nevermind a cutting wheel.

I have bigger problems now, I need a shock tower "right" side, NO longer made.

[mikono14]

hey old goat you can get etch primer at any parts store another good trick for fixing big rust holes like that is go to home depot and buy some great foam expanding foam fill the area with that then tou can shape it with a knife or something like that then you can just use a few sheets of fiberglass on top of the foam and it will last a long time and you can get real close to the right shape

[old64goat]

@mikono14 Thanks, Good tips I appreciate that.

Thanks again.

[callmenort]

taking that bumper off is easy,,just use your grinder to grind the heads off the bumper bolts and knock the rest out with a hammer and drift . no such thing as impossible , and make a template with cardboard as a pattern for your patches,,easier, neater , faster

[old64goat]

@callmenort QUOTE: ",,just use your grinder to grind the heads off the bumper bolts"

Fine if you want to distroy the chrome of the bumper, not that the chrome is all that good.

Besides you can't buy those chrome bumper bolts anymore, I know I tried, years ago in the early 70's I replaced the bumper bolts (chrome) on my 1963 Ford Galaxie now a days you can't buy them.

Template? why bother I just cut the metal larger than the hole, you will see if you watch all the other parts of this series.

[baytrey1]

haha you are good i'll give you that, just get in there and do it. If a tad rangi about it.

[MrAlittle5150]

I like this guy , he's real

[SmoothDonkey]

@old64goat That is some bad news. Used would be an option, but they will likely be rusted out as well. You could fab a new one, or have one made. But it will be time and money the van simply isn't worth. But I'm sure you know that. I had the same decision to make on a car a 3 years ago. And decided it simply was worth doing to get a another year before something else went wrong. Just my 2 cents. Either way, good luck! Maybe post a video of it. It could be saveable.

[ladyowned]

I think you and I would make a great team fixing vans in the back yard. :D

You're very good with fabricating pieces to fit....great video.

[bokbok454]

if a 3/4 inch 6 point doesnt work, try going metric. Get one thats just slightly small and pound it on with a sledge, before hand soak with PB Blaster, heat with MAP gas (much cheaper than the big torches). it can be done, just have to get mad at it.

[TechMaven]

A word on frozen bumper bolts..if you can get a small stiff wire brush in there, clean up the hex nut with it. You'll likely find a socket will fit after getting the rust off.

Then get some PB'laster and soak the nut/bolt with it...after about 5 minutes those bolts will break loose. Take it from a fellow "Poor Man"!!