Stopping/maybe fixing body rust if I decide to keep my current Expedition?

[rwc265]

I think the picture speaks for itself. That's on the driver side underneath behind the rear bumper, passenger side isn't much better. This a common spot for this to happen? And, how can I halt it if I decide to keep this truck?

And how hard are rocker panels to do, they have to be cut out and new ones welded in right? Mine are practically Bluetooth, and on the passenger side at least it's broken through to the wheelwell

 

[BigOleFordFan]

Well, at this point, there is no REAL "fix" for this issue other than cutting out the bad areas & welding in some new steel, preferably 304 or 316-grade Stainless, same for the rocker panels if they are in a similar state....

There are places that sell ready-made replacement panels for the rocker panels for some models, most of which can be either screwed or welded (preferable) into place, but you still need to remove the bad parts first, seal them, and then proceed with the replacements...

In either case, unless you're very handy with a cutting/welding torch & metal grinder, I would recommend leaving this work to a pro...both for quality and safety reasons...

However, this repair(s) aint gonna be cheap, so unless the rest of the vehicle is solid and in very good condition/low mileage etc, I don't think I would put that much $$ into it, unless of course you just have money to burn

 

[GlennSullivan]

As Ford Fan said and I concur, don't just look at 1 or 2 spots. Do a complete visual evaluation of both the body and frame. If it is a few spots and the rest of the body and EXPECIALLY the frame are in good shape, look into repair cost. However, if this type damage is found throughout the vehicle, there is no point.

 

[rwc265]

Well, the frame has two holes right where the front wheels kick debris. The rockers are uh.. very gone lol. I went tapping with my shoe even more and the rockers are just ejecting material. I just wanted to see if there was any economical way of doing it but I don't see me saving this truck. I'm back to the original plan, find a southern one. And realistically even though the rest of the frame ain't that bad, the entire suspension metal wise is, and I'm never gonna be able to halt the rust completely

 

[GlennSullivan]

Yeah. There are a number on posts here on the same subject. Once they get past a certain point, not only are they not realistically fixable, but kind of unsafe to drive and that is not even considering the possible drivetrain failures.

 

[BigOleFordFan]

Well, the frame has two holes right where the front wheels kick debris. The rockers are uh.. very gone lol. I went tapping with my shoe even more and the rockers are just ejecting material. I just wanted to see if there was any economical way of doing it but I don't see me saving this truck. I'm back to the original plan, find a southern one. And realistically even though the rest of the frame ain't that bad, the entire suspension metal wise is, and I'm never gonna be able to halt the rust completely
View attachment 84007View attachment 84008

Woof....yea that's bAd.....and unsafe too !

Had you caught this a few years back, the repairs, followed by a good undercoating (the ONLY real way to stop rust in it's tracks), would probably have saved this Expy from it's slow, painful death

Hopefully you can find another one in better condition, and perhaps sell some parts off this one for somebody who is refurbing another one

 

[JExpedition07]

There is no excuse for the rocker panels, Ford used crap steel with poor drainage. It usually starts around the 4 year mark.

I don’t think the kickers offer much safety. In a side impact I doubt my brand new F-150 fairs much different than my old rusty Expedition would have. They are tin foil even when brand new, more aesthetic pieces.

At the point you are at I wouldn’t sink money into it.

 

[rwc265]

Yep. I knew buying the thing there was a good chance it'd be short term. I got it for just 2 grand and only did power steering lines and struts because they were critical. Even by NJ standards, it's really rusty but before I went looking and exposing it, it didn't look bad. I think this has spread past even what a full OEM rocker replacement would fix. Plus all the other body and paint work that needs to be done, plus the suspension work and considering all the suspension arms are really rusty too, I definitely can't justify it, and frankly don't wanna spend my time doing it lol. Back to plan A, bring a southern Expedition or Navigator back here, paint and undercoat it, then hold on to my full top end and timing parts until it needs it. There's more pics of how it is... very ugly. Shame because the frame is fine except for the two very patchable holes. Also notice the one picture. The door seal at the bottom has nothing left to seal against anymore...

 

[2016 ford expo]

do you have a junkyard were you can take parts off cars. if so I would say cutting of good parts from one at the junkyard and cut out rust affected areas then weld the good parts in.

 

[rwc265]

NJ doesn't let you go into the junkyards unfortunately. Plus, it's a lot of welding at this point. Methinks it's still time to surrender

 

[GlennSullivan]

If you really had the time, energy and money, the only option with the current vehicle I could see (not advised) would be purchase a bad motor / good body donor and do the fankenstein thing. Again not advised.

What I would do if find a farmer (lots in NJ and PA) that needs a farm vehicle and does not care what it looks like.

 

[2016 ford expo]

patch kits are wildly available. do have friends in a different state that can pick up the parts and ship them to you

 

[rwc265]

Yeah, but I mean at this point it's an SSV I would be fighting to save anyway. For the price of patching and fixing it all, there's far better optioned Expeditions, some even cheaper than I would pay to patch.