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Lazy man's body panel "repair"

Own a really old Isuzu? Tired of rusty lower body panels and too cheap / lazy to do actual body work? Welding skills would make it worse? Want a simple weekend fix for around $60 that looks okay from 4 feet away?

Well I sure hit that point, so I made a Menards trip and grabbed a few basics:
  • 6 pieces L-shaped rectangular metal duct @ $5 each
    1 sheet metal folding tool @ $8
    3 cans Rust-Oleum rubberized undercoating @ $3 each
    2 cans Rust-Oleum semi-flat @ $3
    1 tube construction adhesive @ $4 (or molding adhesive)
    1 box metal stud screws @ $4
    1 bottle navel jelly + brush $4
    1 15' 3M molding adhesive roll $15

Grabbed by toolbox:
  • straight snip
    grinder/drill wire-wheel
    sandpaper
    hammer

Drink something to dull your good judgement, then pull off the body molding (because only real isuzu's have 'em), and wire-wheel to remove as much rusty crusty from bad areas. Apply navel jelly and let it eat it up the angry MN winter stuff, rinse clean and dry. Paint to hide the ugly remainder (or POR-15 it if you are ambitious). Now the fun part - snip duct work sections to fit areas of body panel to fit at modeling seam and below, leaving enough to have edges folded and shaped to more or less fit existing sections. Used the smaller L section of the duct to cover the existing panel to under-body curve. Took about 15 minutes per section if you don't measure/care to hard and have a hammer to help out the anger. Easier than I expected. Rough up the smooth ducty metal and rattle can with undercoating. Wait a day for it to dry because you bought the cheap undercoating. Glue into place, and use metal screws to attach where molding will cover seam. Optionally throw a few more screws to strengthen where needed and hiding behind bumper caps or what not. Hit up more undercoating, and top off with some semi-flat. Make sure not to stop and take pictures, because the evidence would be embarrassing if you remembered what you did after the drink wore off.

Close enough! And now the neighbors care slightly less about what they see across the yard. Just don't kick it to hard. 

Troopers are awesome. Especially if they are old enough to drink.
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clean1.JPG
(314k)
Joe Samek,
Jun 2, 2015, 7:25 PM
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clean2.JPG
(310k)
Joe Samek,
Jun 2, 2015, 7:25 PM
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driver.JPG
(395k)
Joe Samek,
Jun 2, 2015, 7:25 PM
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Joe Samek,
Jun 2, 2015, 7:25 PM
ą
Joe Samek,
Jun 2, 2015, 7:25 PM
ą
Joe Samek,
Jun 2, 2015, 7:25 PM
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