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Time for some rust repair on the Tahoe.

Driver side cargo area floor is done.

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Next I fixed the rear frame crossmember that was rusted through from the foam between the crossmember and gas tank trapping moisture.

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Now I’m working on the passenger side. The damage is spread out a lot less, but it went a bit deeper because the crossmember was also roached. So next I’ll be rebuilding that and then fixing the floor.

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I got the passenger side fixed today. First I made a new patch section for the crossmember.

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Once it was welded in I painted Rust Seal on the internal surfaces for future protection. No picture of the paint unfortunately.

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I also patched a small section of floor further up.

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Then I made patch panels for the floor.

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Here are views all around the repair.

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Unfortunately while admiring the finished job I found more pin holes in the floor. I thought I was done, but it looks like I have another week to go. Ugh.
 
Finally wrapped up floor repairs this weekend. All of the patches are complete.

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Today I applied the KBS Rust Blast to the underside just to make sure that the rust was taken care of and the fresh sheet metal was etched for optimal paint adhesion. I had 1 gallon and 1 quart of the product, but I wished I had 2 gallons - you are supposed to keep the product wet while it’s working and I didn’t have any left to keep misting on it. So I misted a little water on it for a few minutes, but then I started rinsing it with water after that. I probably got 30 minutes of soaking time, but I really wanted to do it for 60 minutes. Oh well, you can sure see the zinc phosphate coating that it deposited on the metal.

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This week is prep work so I can paint the underside next Saturday. That will be a big step!
 
Tonight I did some axle prep. A couple of the brake line retainer tabs had broken off so the fix I came up with was to grind them off and weld tapped blocks to the axle. I bought some stainless steel tabs that will clamp the brake line down to the blocks. I think it will look kind of trick when it goes back together.

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