Wheel Well Rust Repair

I've purchased the wheel well replacement panels and will be replacing them this next week. I'll post pics of my progress. The panels if I can use them correctly will remedy the rust above the wheel well, but I've not been able to find how to remedy the rust immediately in front of and behind the wheels. any suggestions or references would be appreciated.

My brother says I should try to find a complete bed, and I see merit in his suggestion, but I've not found a suitable bed in my searches.

I see some tacos on here where they have constructed a flat bed....that may be an option, but I sure like the looks of 1st generation Red Tacos... I have a 96 and a '04.... both have some rust issues, but still run and drive great.

Thanks in advance for any suggestions!!

 

I am also looking for replacement parts for the '04 skid plates and the plate protecting the gas tank on the '04.

 

If you're having bed rust issues, how's the frame? In my experience the frame rusts faster than the body unless something happened to the body panels.

 

So far the frame looks to be solid. There is some rust on it. I'm headed out to try and weld the replacement panels today. I'll post pics of my progress and I can only hope it goes smoothly.

Enjoyed reading about your build.. I'm working to get my e-brake working again. I have the initial part freed up, but the cable to the back brakes is still stiff. The person who sprayed the undercoating was very generous with the material...I may find he/she covered up some frame compromise... I'll keep everyone posted...

The link to the skid plates on your build seems a bit old... is the fellow who provided those skid plates still in business. I have lots to learn in this area...

Thanks for your post...

 

Progress today

 

Wow if the body is that bad I would really inspect that frame. Hit it with a hammer in a few places.

 

X2^^^

 

Looking at the parts of your frame that I can see in those pics, it looks as bad as mine. At least check the handful of trouble spots like around the spring hangers. Remember, the frame on these trucks tend to rust from the inside out.

 

Made some progress but our fiberglass mix lacked hardener. Lower portions of the quarter panel are a challenge for DIY body men.

 

Could be worth it to just get glass bedsides? That way you could just cut the rest off and start over without having to blend the two. Im not a body work guy, but I cant imagine the blend of glass to metal like that would be the best combination in the long run although glass will crack the paint regardless in time.

 

Why bother hacking and spackling, when you can buy a new complete rear wheel arch panel (bed side panel) from Rock Auto for under $75+shipping?

Just need to drill out the spot welds and weld on the new on. Add paint, and Bob's your uncle!

http://www.rockauto.com/en/catalog/toyota,2004,tacoma,3.4l+v6,1429084,body,wheel+arch+panel,18519

 

On second thought, it looks like this is mostly just the arch, and is still a weld in patch. Not the entire fender as I was seeing it.
My bad!

 

This is why having fender flares is a bad idea. it traps mud and moisture and when you see signs of rust, it is already too late (because you don't see it until it is)
I would ditch them after this repair, or the story will repeat itself. Or keep them and regularly remove them to clean the wheel arches and the flares

yeah, it is just the patch for the wheel arch, not the whole fender

 

Yes, I looked for the entire quarter panel and haven’t been able to find one. If you come across one let me know.

We are going to do some inspection with s hammer. My brother is giving me smack saying don’t hit it to hard...maybe all thst’s Holding it together.

We are having a good time... two old retired Texas boys.

Thanks for all the posts!!

I’m going to call Toyota customer service and see if there may be some other options.

 

I would call as soon as possible, you have a 2004 and you have one of the last trucks to qualify for the 15 year recall depending on the in service date.

 

Yes, been on the phone with the dealership and Toyota, got conflicting reports initially. Toyota initially said it was eligible for frame replacement..a call to the local dealer and they say it has been replaced. A call back to Toyota and they now say the frame has been replaced.

So I’m back to looking at my besft options regarding this Tacoma.

They say the criteria for replacing the frame is to hit frame with ballpeen hammer and if it goes through the frame then it is eligible for replacement then and Toyota will do it.

I don’t have any areas where this is occurring.

Hey, really appreciate the TW members and their input...it’s a bit lonely dealing with this rusty Tacoma, but you folks are encouraging.

 

Wow, just can’t fathom that much rust on a ‘04- I just sold my 2002 and it was clean- difference between the rust belt and sun belt. I feel for you though, that must be heartbreaking to see your rig do that, some even starting out with signs at 2016! Anyways, I always liked these- Maybe you could do so much better than rebuilding that bed - make a red expedition rig with style:

 

I’m open to any and all ideas.

Thanks for the suggestion.

I actually have two Tacoma’s. I’ve had my 96 for about 5 years it has just over 130k and has been rock solid, bought this 04 because it seemed a really good deal. Time will tell on that.

 

You're saying Toyota said the frame on the '04 is brand new?

 

Our 1985 was rust proof too when we sold it. We’re lucky out here in the desert for that, but have other issues like wire eating rats!!