Quote:
Originally Posted by Moneyguy1
[expandable foam which in turn would it self require sealing.
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I used it on my hovercraft, it will suck moisture right out of the air and fill up with water (condensation), I don't think any amount of sealing will prevent this. Trust me, I considered it.
I understand that POR-15 may be a better product than Permatex, but you can't paint over it without an application of a second primer product from them. This makes me nervous because I don't know how fiber-strands soaked in epoxy would attach or bond to it.
All products I mention using in this thread I have used and have in stock because of my Tracker or hovercraft. I'm going with what I know, and I know many standard automotive products like plastic body filler (Bondo) are not up to my personal quality standards.
Here are the next steps (in my mind);
1. I foil tape the lower inside arch and wheel well, this will make a temporary form mold.
2. I epoxy soak fiberglass strands and suff then into the open cavities/rust holes.
3. Using a flappy sanding wheel on my drill I burnish off the foil tape and any messy or sharp strands of cured fiberglass.
4. With any voids now 1/4" of less in depth I putty in a stiff/thick mud of micro balloons or other epoxy based filler.
5. I grind down anything and everything. I then sand by hand with 200 grit in prep for glazing putty or feathering putty (finer than micro balloons).
6. I do final prep for primer and finish coat, sanding and filling as required.
7. On the inside of the wheel wells I spray on truck liner or tar-like rust proofing.
8. Clean up and touch-up paint exposed areas.
9. Install Flexy Flares.
10. Paint zebra stripes on upper body and paint alum. wheel rims black.
11. Install front home made chin spoiler, to save on gas.
12. Hook up the trailer and head off to a Hoverally.
EDIT : 3/16/09
I think (hope) the repair will last five years, the rubber lips will help hide it for another two. This 11 year old truck will then be 18 years old and a total wreck like the Tracker was at the same age.
I don't weld (the right way to do this repair), that's no excuse it's just a fact. By the time I learn to weld right, I'll be done.
I need to glass the backside and fill in the deeper pits (after scuffing it up). Several more steps, but this is going quickly, might be all done by Sunday.
The other side:
I used tape to form a mold on the rusted thru-holes and once it was setting up pulled it off so it would cure on both sides.