i would just buy a d1 with less rust and swap any new or custom parts onto it from your old truck.

 

I have tested the post-sanding stuff with a hammer. How hard do you hit it? I was going less than a nail strike, but firm enough to rattle rust off.

Also, I got a 4.5" angle grinder from HF. It seems to work alright. Ill know more when I try to cut with it.

 

From what I can see you're going to have to do a LOT of cutting welding. However, if it were me I would only do it in the front of the passenger cabin, meaning under the seats and up to the firewall. That should make it safe passengers and an accessible job if you're handy with a welder. I'd leave the back alone as long as the frame is solid. But definitely use a grinder to get to bare steel and rattle can it.

Disclaimer: I watch a lot of fix-er-up car television and have seen this done, but I have never done it myself. If you're like me, I'd take it to a professional, but just for those safety areas.

 

Haha, yah.

Im from Hawaii and live in Minnesota now. If your car didnt eventually develop something, its because you were borderline maniacal about washing it.

 

You could use this as a really good excuse to buy a MIG welder and learn a new trade. Then again I love tools so I'm always looking for an excuse...

 

I thought about it, but its like $300 just for the cheap harbor freight stuff.

 

...you know what would suck....spending a lot of time on it only to have it continue to deteriorate...everytime i see one of those cheap D1's going I wonder if I made the right decision..for a bunch of reasons. having said that, i love my truck and am glad i did. but short of welding, which is no doubt the best way to handle it, i did my best to permanently fix my rust if there is such a thing. which there isn't. i want my truck to look good for all the time i spend on it.

my process was grind/cut/treat/rust paint/rivet and in some places paint again. i used the kbs rust system and the results are good. thanks for the op to show em again...

 

I have repaired two Discos and a Defender that had significant rust damage.

For me to fix that, you'd be looking somewhere in the $2500-$5000 range. I can just about guarantee that when the front wings are removed, there will be significant rust on the side of the bulkhead and the inner fender sheetmetal.

There is a reason I tell folks to look for trucks with the least rust they can find.

 

See, now you can easily justify buying a welder. Or a different truck...

 

Wow, seriously nice work, Slang. The result is something I'd almost cut out good sheet to attain.