Suburban rear door jamb rust fix

[2manyburbans]

I was wondering what is the best way to repair the upper door jams on the suburban model I have a donor truck but I have to cut parts myself and I'm not to sure on how I would cut this section out or are there alternatives to fix this area

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[TotalyHucked]

Yikes. I'd be finding me a new truck. That's the worst possible area to repair

 

[2manyburbans]

Yikes. I'd be finding me a new truck. That's the worst possible area to repair

But it can't be impossible like I said I have a solid donor I can cut on would that even matter and I'm working with a very competent body shop

 

[TotalyHucked]

But it can't be impossible like I said I have a solid donor I can cut on would that even matter and I'm working with a very competent body shop

No, it's not impossible. But the problem is there's multiple layers of metal right there. There's the inner C-pillar structure, the door surround, the quarter panel and then the roof skin. If I were going to attempt it, I would cut the parts truck right behind the B-pillar and halfway down the quarter, all the way to the middle of the truck. That way you have plenty to work with in case you find more rust (and you will) underneath. But that is going to be a nightmarish repair.

 

[bucket]

I disagree. I think that's a minor repair, and a good one for beginners too. Cut out the roof skin of the effected area, just large enough to also have good access to that outer layer of jamb area. Then cut out the bad area of the jamb. Cut out more of the donor than you will need, then separate the donor panels. Then trim them down as needed, to weld into your truck.

I say it's a good repair for beginners because it's a small area and much of the bodywork will just be in the jamb. The bodywork to the roof skin is up high and not obvious to spectators. The hardest part will be welding it in without blowing holes in the sheetmetal, if that's not something you are familiar with doing.

I definitely would not be looking for a new truck because of that.

 

[2manyburbans]

No, it's not impossible. But the problem is there's multiple layers of metal right there. There's the inner C-pillar structure, the door surround, the quarter panel and then the roof skin. If I were going to attempt it, I would cut the parts truck right behind the B-pillar and halfway down the quarter, all the way to the middle of the truck. That way you have plenty to work with in case you find more rust (and you will) underneath. But that is going to be a nightmarish repair.

Thank you for your honesty I would get a new truck but the market down here in florida is very slim you especially for the burbans you either get rust bucket or a $25,000 show truck but I will keep the forum posted and again thank you

 

[2manyburbans]

I disagree. I think that's a minor repair, and a good one for beginners too. Cut out the roof skin of the effected area, just large enough to also have good access to that outer layer of jamb area. Then cut out the bad area of the jamb. Cut out more of the donor than you will need, then separate the donor panels. Then trim them down as needed, to weld into your truck.

I say it's a good repair for beginners because it's a small area and much of the bodywork will just be in the jamb. The bodywork to the roof skin is up high and not obvious to spectators. The hardest part will be welding it in without blowing holes in the sheetmetal, if that's not something you are familiar with doing.

I definitely would not be looking for a new truck because of that.

I'm working with a very good body shop they've been in business under the same owner for 65+ years I'm going to listen to both of you guys and cut way more than I need and then let the shop do the rest thank you guys

 

[TotalyHucked]

Thank you for your honesty I would get a new truck but the market down here in florida is very slim you especially for the burbans you either get rust bucket or a $25,000 show truck but I will keep the forum posted and again thank you

Oh I definitely understand. I hope it works out for ya and they're able to fix you up. I work in the restoration parts biz (AMD) and rust in that area always makes me cringe cuz I know how they're put together. It won't be easy but a skilled metal guy can do anything. Best of luck!

 

[Grit dog]

I’m no pro like some of the guys who say that’s an easy or good beginner job. Only good part of it for an amateur IMO is it’s either hidden, able to be smeared with seam sealer or on the roof where it’s hard to see later. Have done
Here’s what I would do if going forward with it, and have a donor vehicle. Take both sides. Cut open and practice/plan what you’re gonna do with the off side that you don’t need. Will eliminate most of the surprises and rework that way.
It will be a project. I did some metal patching around the windshield/a pillars and roof on the 86. Got lucky that it was just the skin that was rusted out. But I spent a lot of hours on not a lot of work, comparatively.

 

[TotalyHucked]

^That's a great suggestion, practicing on the donor

 

[bucket]

I’m no pro like some of the guys who say that’s an easy or good beginner job. Only good part of it for an amateur IMO is it’s either hidden, able to be smeared with seam sealer or on the roof where it’s hard to see later. Have done
Here’s what I would do if going forward with it, and have a donor vehicle. Take both sides. Cut open and practice/plan what you’re gonna do with the off side that you don’t need. Will eliminate most of the surprises and rework that way.
It will be a project. I did some metal patching around the windshield/a pillars and roof on the 86. Got lucky that it was just the skin that was rusted out. But I spent a lot of hours on not a lot of work, comparatively.

Yeah, that's why I said good for a beginner, because it can mostly be hidden. Or at least, it's an area that won't stand out like a sore thumb if the work is kinda shoddy.

Honestly, as long as the rust gets cut out and some kind of metal attached back in place to seal it off, it will be fine. Then doctor it up to look presentable. Like the saying "Do your best and mud the rest".