Fixing Rusted Truck Bed Supports: A Step-by-Step Guide

Understanding the Extent of Rust Damage

If you’re an owner of a truck, one of the critical things that need to be kept in check is the rust in the truck bed supports. Rust can compromise the structural integrity of your truck bed, leading to significant safety issues once you start carrying loads. An inspection is essential in determining the extent of the rust damage, so you need to assess the truck bed supports to determine the rust extent. With that said, rusting can happen in various forms, causing rust damage in various ways. In this subsection, we’ll explain the various forms of rust and the extent of the damage it might have caused your truck bed support.

Surface rust is the most common form of rust. It’s a result of moisture accumulating on the metal surface and reacting with it after a long time. Surface rust doesn’t cause significant damage and only affects the exterior surface of the steel. After inspecting the truck bed support, you’ll notice that the color has faded in some areas, leaving behind brownish spots. If the surface rust has eaten through the uppermost layer, the next layer is exposed and prone to moisture, accelerating the rusting process. You can easily fix surface rust with sandpaper and a rust inhibitor.

Scale rust often occurs when the rust caused by surface rust grows over a long time, with no preventive maintenance to check it. This rust type becomes rough and flaky, indicating that lots of layers have already built up. Scale rust usually represents extensive rust damage, and it’s essential to act fast to prevent further complications. Scale rust means that the rust has gone through to the metal’s core, and it can cause considerable weakening of the truck bed support’s structural integrity leading to safety hazards if not taken care of immediately.

Pitted rust is the most advanced form of rust damage. It is usually caused when scale rust damage is left unattended, leaving the metal surface instead of getting rid of the rust. As the rust continues to consume the metal surface, it forms pits that quickly weaken the structural integrity of the metal until it becomes irreparable and needs replacement. At this point, you’ll notice your truck bed supports are discolored, rough, and even wearing off in some areas.

When assessing the extent of rust damage, it’s essential to take time and examine all the sections of the truck bed supports. If you wait too long to inspect and fix your rusted truck bed supports, you might end up with costly repairs that can be avoided with active preventive measures. Regular maintenance is essential, as it prevents long-term damage to your truck bed support and ensures that it’s safe for transport.

In conclusion, each rust form indicates the level of severity of rust damage. Surface rust is the least severe while pitted rust is the most severe. Therefore, it’s crucial to understand the extent of the rust damage before deciding on the most appropriate action to fix it. If the rust damage is extensive, it’s best to consult with a professional instead of attempting to fix it yourself. Act swiftly and fix any rust damage as soon as you spot it to protect yourself and others who use your truck bed.

Gathering Necessary Tools and Materials

There is nothing more frustrating than discovering rusted truck bed supports, but with the right tools and materials, it can be fixed with ease. Before starting the repair process, gather all the necessary tools and materials you will need. Here is a list of everything you will need:

Tools

• Electric drill with wire wheel attachment
• Grinding wheel
• Hammer
• Lubricant
• Safety glasses
• Gloves
• Bolt cutters
• Adjustable wrenches
• Screwdrivers
• Flat metal file

It is essential to have the electric drill with a wire wheel attachment. This tool is used to remove all the rust from the truck bed supports. Similarly, the grinding wheel is used to grind away all the excess rust. The hammer and lubricant comes in handy when removing rusted nuts and bolts, making it easier to remove and dismantle your truck bed supports. Wearing safety glasses and gloves is recommended to protect your eyes and hands from the debris that will be flying about when drilling, grinding, and hammering.

Materials

• Steel mesh
• Rust converter or rust inhibitor spray
• Fiberglass resin and hardener
• Paint
• Premium truck bed liner
• Self-tapping metal screws

The materials you will need include steel mesh, rust converter or rust inhibitor spray, fiberglass resin, and hardener. The steel mesh will provide additional support to your truck bed after repairs have been made. Rust converter or rust inhibitor spray will help stop rust from spreading and thus prevent further decay. The fiberglass resin is used for sealing holes and covering the steel mesh after it has been attached. The paint and premium truck bed liner are optional but can give your truck bed a brand new look. Moreover, it will prevent rust from forming in the future. The self-tapping metal screws will be used for attaching the steel mesh to your truck bed supports.

Having all the required materials and tools will make the process much smoother and hassle-free. Plus, it is essential to ensure that they are of good quality to provide long-lasting results and prevent further rusting of the truck bed supports.

Removing the rusted truck bed supports

If you’re noticing that your truck bed is sagging or bouncing a lot while driving, chances are you have rusted truck bed supports. These rusted supports can be a safety hazard and need to be addressed. It’s possible to fix rusted truck bed supports with the right tools and knowledge, and we’re here to help. In this subtopic, we’ll cover the steps on how to remove rusted truck bed supports so you can continue with the repair process.

Before removing the rusted bed supports, you should take the necessary precautions to ensure your safety. Wear safety glasses to protect your eyes from rust particles that may be flying around during the removal process. Also, wear gloves to protect your hands from sharp metal edges.

To remove the rusted bed supports, you’ll need the following tools:

• Socket wrench set
• Drill
• Drill bit set
• Reciprocating saw
• Penetrating oil
• Hammer

Now that you have the necessary tools and safety gear, let’s dive into the steps on how to remove rusted truck bed supports:

Step 1: Spray Penetrating Oil

Spray some penetrating oil on the rusted bolts and nuts that are holding the bed supports to the truck. Wait for several minutes for the oil to soak in and loosen the rust.

Step 2: Remove the Nuts and Bolts

Using a socket wrench set, remove the nuts and bolts that hold the bed supports to the truck’s frame. If the nuts and bolts are too tight, apply some more penetrating oil to loosen them up, and then try again. Be sure to keep track of the nuts and bolts as you’ll need them later for the repair process.

Step 3: Cut the Bed Supports

If the bed support is too rusted and stuck on the truck’s frame, you may need to cut it out. Use a reciprocating saw to cut the bed support between the rusted area and the truck’s frame. Be careful not to cut into the truck’s frame. After cutting, remove the bed support and dispose of it properly as it’s no longer needed.

Note: Cutting the bed support is not always necessary. If you’re lucky and the bed support comes off easily after removing the nuts and bolts, you can skip this step.

Step 4: Sand the Truck’s Frame

With the bed support removed, you’ll notice some rust and leftover pieces on the truck’s frame. Use sandpaper or a wire brush to remove the rust and leftover debris on the truck’s frame. This is an important step as it will be easier to attach the new bed support once the truck’s frame is clean.

Removing rusted truck bed supports can be a challenging task, but it’s necessary for the safety of your truck. With the right tools and precautions, you can remove rusted bed supports and continue with the repair process. After removing the rusted bed supports, you can move on to the next step, which is how to install new truck bed supports.

Installing new truck bed supports

If your truck has rusted bed supports and you are looking to install new ones, then you are in the right place. The process of replacing truck bed supports is not as complex as it may seem, but it requires some basic knowledge, tools, and preparation. Here is a comprehensive guide on how to install new truck bed supports:

Gather the necessary tools and materials

Before you dive into the process, it is essential to ensure that you have all the necessary tools and materials. Here are some of the tools and materials you will need:

• Welding machine

• Cutting blade

• A metal grinding wheel

• A drill bit for metal

• A reciprocating saw or hacksaw blade

• Rust-resistant paint and primer

• New bed supports

• Measuring tape

Remove the rusted bed supports

The first step is to remove the old and rusted bed supports. Start by using a cutting blade or reciprocating saw to cut through the old supports. If there are bolts or nuts holding the bed supports in place, remove them using a wrench. Be sure to save those hardware pieces, as you will need them when you install the new bed supports.

Prepare the truck bed for new supports

After you have removed the old bed supports, you need to prepare the truck bed for the new supports. Remove any remaining rust, debris, or paint using a metal grinding wheel. You can also use sandpaper or a wire brush to smoothen the rough areas. Also, clean the area with a cloth soaked in paint thinner or solvent to remove any grease, dirt, or oil that could prevent the paint from properly adhering.

Measure and cut the new bed supports

Once you have cleaned and prepared the truck bed, measure the length and width of the area where the new bed supports will go. The new supports should be of the same size and shape as the old ones. Use a cutting blade or saw to cut the new bed supports to the desired size.

Weld the new supports to the truck bed

With the new bed supports cut and prepped, it is time to weld them onto the truck bed. Place the new supports where the old supports used to be and weld them into place. You will need to use metal clamps or magnets to hold the new supports in place while you weld them. Be sure to make multiple passes with the welding machine to ensure that the bed support is securely attached to the truck bed.

Paint the bed supports

After the new bed supports have been welded in place and cooled down, it is time to paint them. Apply rust-resistant primer to the entire area where the new bed supports have been installed. Let the primer dry completely, then apply rust-resistant paint. Apply at least two coats, allowing each coat to dry before applying the next one.

Reinstall the truck bed

With the new bed supports installed and painted, it is now time to reattach the truck bed. Use the saved hardware to fasten the truck bed securely onto the new bed supports. Tighten all the nuts and bolts to ensure that the truck bed is sturdy and safe.

Installing new bed supports is a crucial process that requires patience, preparation, and the right tools. By following this guide step by step, you can rest assured that your truck bed will be sturdy and safe to carry heavy loads.

Preventing future rust damage

Now that you’ve fixed your rusted truck bed supports, the next step is to make sure it doesn’t happen again. Here are some tips on how to prevent future rust damage:

Wash your truck regularly

One of the biggest culprits of rust is the accumulation of dirt and grime on your truck. This is especially true if you frequently drive on dirt roads or in areas with high amounts of salt on the roads. Make sure to wash your truck regularly, especially the undercarriage which is often the most susceptible to rust. Use appropriate detergents and avoid using harsh abrasives that can scratch your paint job or cause damage to your truck bed supports.

Apply a rust inhibitor

Another way to prevent rust on your truck bed supports or any other metal component of your vehicle is to apply a rust inhibitor. Rust inhibitors create a protective barrier between the metal and the environment, preventing water and oxygen from reaching the metal surface and causing rust. There are many types of rust inhibitors available on the market, and you can choose one appropriate for your needs. Be sure to apply it properly according to the instructions included in the product.

Keep your truck in a dry and covered environment

Storing your truck in a dry and covered environment can further prevent rust from developing on your truck bed supports or any other part of your vehicle. When your truck is exposed to moisture, it can speed up the rusting process and cause damage. If you can’t keep your truck inside a garage or other covered space, consider using a car cover to protect it from the elements.

Maintain your trucks paint job

Lastly, a properly maintained paint job on your truck can help prevent rust from developing, including on your truck bed supports. A strong, intact paint job helps protect the metal underneath from oxidizing, keeping it dry and preventing rust from developing. Make sure to fix any chips or scratches on your truck’s paint as soon as possible. Applying a wax or a sealant can also provide further protection from the elements.