Now that we’ve seen what’s underneath and waiting in store for us - the only way out is through.
The below photos show the extent of the rot. Both the outer truck bed skin is rusted, as well as the internal structure piece that is is connected to.
In order to properly address this - I started by removing the inner structure. The spot welded sections were rotted and broke apart easily, however I did have take a large cut into the main structure higher up.
This cut went through both the outer skin & the inner structural member. With the inner structure removed, I began to fabricate a replacement. I started with measurements on a piece of 18GA cold roll.
A couple folds later and we’re sneaking up on the rough dimensions.
A bit more tweaking, hammering and swearing and we ended up with a piece that will work.
Clamping into place to verify fitment.

That should work out fine. Now we need to jump onto the outer skin that will get hemmed to this inner structure.
First we mark the cut line -
There’s some pretty thin steel in there, so kept the patch large enough to tie into good steel, but as small as I could.
Then I moved over to the sandbag to start shaping up some steel to put into place.
Starting to take some form - through it threw the wheel a couple of times to add a small amount of shape and take some of the hammer marks out.
Next up was quite of trimming, measuring, etc and tacking into place before finish welding.
More to come…