97 Yukon GT “Rustoration”

[YukonGTmaster]

I have embarked on the task of eradicating the rusted panels on my 2 door. I have all the common Canadian GMT400 rusted areas. Lower rear quarter, lower door skins, rocker panels, and wheel arches. I purchased the body repair panels from LMC Truck and Mill Supply.

I started today by removing my rear fender flares. Anyone thinking of attempting this should consult this Youtuber. He has been to the mountain top.

I ordered GM P/N 15709267 (Flare Nuts) off EBay for a criminal price. They do NOT fit. The original studs are 5mm. These nuts looks like they are a 3/8 thread. I was able to source some 5mm stamped PAL nuts from Gregg Distributor.

I can keep you posted on my progress.

 

[Tonyrodz]

Nice. Glad you're gonna save it before it gets too far.

 

[YukonGTmaster]

Cutting out the rear lower quarter and wheel arch.

 

[YukonGTmaster]

Inside of lower forward rear quarter. Rust cleaned up, ready to weld in new section.

Bumpers sandblasted. Pinholes through driver’s side front corner.

 

[Tonyrodz]

Inside of lower forward rear quarter. Rust cleaned up, ready to weld in new section.

Bumpers sandblasted. Pinholes through driver’s side front corner.

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Nice. Wish I knew how to do body work.

 

[YukonGTmaster]

Passenger Rear quarter sealed up.

 

[YukonGTmaster]

Front Fenders are off. Taking things apart is easy, it’s the putting back together properly that’s tough.

 

[YukonGTmaster]

Passenger rocker and backing plate....rough shape

 

[YukonGTmaster]

Still going. The front fenders were quite rusted out. I could order new front fenders, have them shipped to Canada, wait 4 weeks, try to put them on….not fit…

We are going to fix the originals.

 

[YukonGTmaster]

Some of the fender flare studs are rusted beyond all recognition. I purchased a 5mm threaded rod, 5mm push retainer washers, and cut some backing plates out of aluminum. (I have no steel or a welder at work.) I cut the rods to 2cm. I tapped a hole in the tabs and epoxied the studs inside. It’s as close as I can get to the original. They don’t offer the studs from GM as they were part of the OEM flares.

 

[YukonGTmaster]

Rusted door skins being replaced.

 

[Tonyrodz]

Rusted door skins being replaced.

Was she really rusty, or just being preventive with it?

 

[YukonGTmaster]

Was she really rusty, or just being preventive with it?

She was rusty and crusty at the lower door skins. Once it was opened up, it was apparent the lower inner door had to be replaced as well. All the surrounding metal is treated with Corroseal and sprayed with sealing wax. I am hoping to drive it another 25 years.

 

[Tonyrodz]

She was rusty and crusty at the lower door skins. Once it was opened up, it was apparent the lower inner door had to be replaced as well. All the surrounding metal is treated with Corroseal and Soayed with sealing wax. I am hoping to drive it another 25 years.

It's awesome you know how to do your own work. Saving a ton of $$$.

 

[YukonGTmaster]

Final sand, and masking up for paint.

 

[Tonyrodz]

Final sand, and masking up for paint.

Finally! The light at the end of the tunnel!

 

[YukonGTmaster]

Smooth.

 

[YukonGTmaster]

Back on the road today. Putting the interior back together, and mounting the rear fender flares.