I assume every build comes across a (few) problem(s) that are unexpected and disappointing. Today, Matt and I have really reached our fill of frustration. When we bought this truck and did our inspection we saw some small rust in common places but, man, was that just the tip of the iceberg. This truck cab is rusty to the point we’re considering buying a new cab.

There’s rust in the roof, the top windshield support between the A pillars, lower half of both doors inside and outer skins, the floors, rockers, cab corners and floor supports. There’s pitting in strange places in the cab becuase the guys who chopped the top didn’t seal the windshield right and to stop leaks they slathered silicone caulking all over the place which had the effect of retaining water rather than sealiing it out.

Also, some previous owner worked hard to cover up the rust, on the passenger rocker they glued a good rocker over the rusted out one. What looked solid wasn’t even lipstick on a pig, it was lipstick on a skeleton. Everytime we find body filler it’s 1/2 inch think and covering some bubble gum and bailing wire and rust … rust … rust. If the owner had put as much effort into attching actual metal as they did on shaping acres of bondo the truck would be solid. Feh

We bought the truck because we love the chop but, we hoped for a different type of project and a shorter time line. The amount of metalwork on this truck is massive and it’s slow going when you only get to work it a few hours on Sundays. Lesson learned, get that prospective buy up in the air and really dig. A lot of rust could have been discovered if we’d put it up on a lift or brought a floor jack and took a peek underneath. You just don’t get a good enough look at the condition under a vehicle that’s dropped low no matter how good your flashlight.

So what to do? Go to the junk yard and get a new cab and doors or stick with the chop and weld, weld, weld? The last few weekends have been lousy with rust, but we’ll figure something out.