How To Fix A Leaky Cooler

Loquinho [OP] Member

Joined:

Mar 15, 2016

Member:

#181346

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16

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Male

Richmond, VA

Vehicle:

2002 Green Xcab 5VZE 4x4

OME Susp Marlin clutch 212K miles Frame Replacement

My truck is starting to lose its clearcoat pretty bad on top of the cab and hood, so I decided it's up for a repaint. I've owned the thing since '02, so it's almost at its 20th anniversary with me. It got put on a new frame a few years back, so it's good to go for MANY years to come... I just need to help the body last as long as the frame.
I went under the truck and poked around to see what needs to be addressed before repainting, and I found a couple spots of concerning rust under the bed. I'm not sure if I should be sourcing a new bed for the truck before repainting, or if these are fairly straightforward repairs to have made. I'm pretty mechanically inclined, but welding and bodywork is NOT one of the skills I possess. So I turn to the forum for wisdom.

Here's the first spot. We're looking in the passenger side wheel well. This spot along the inside edge of the bed has rusted completely through - I think the bedliner is the only thing holding it all together at this point. It wasn't very visible until I dug into it with the screwdriver. Then all the layers just came apart. It was hidden from this outside by the factory undercoating, and from the inside by the bedliner.

And here's where that spot is inside the bed - the screwdriver head is pointing right at it.

Here's the second spot: We're looking straight up in front of the driver's side wheelwell at the brace that provides rigidity to the front corner of the bed. This one all opened up when I poked with the screwdriver as well.

And here's a close-up of that area.

From what I can tell, those are the only two problem spots. Everything else is in ok shape for its age. The cab appears to have been fairly well protected by my perpetually leaky valve covers, which have covered the underside of the cab in a nice sheen of oil... I need to fix that at some point too.

SO! Are these areas fixable by someone that knows what they're doing? Are there replacement patches from Toyota or are we looking at custom fab work, and should I just give up and pick up another used Tacoma bed instead? I think I got a lead on one for $800, but I don't know what kind of shape it's in either.

As always, thanks ahead of the time for assistance. I've been using Tacomaworld since my truck was still considered a fairly new truck. I'm not on that often, but enjoy the knowledge base here.

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Bivouac Well-Known Member

Joined:

Sep 5, 2021

Member:

#376253

Messages:

1,267

Northern Lehigh Valley Pa

Vehicle:

2000 Tacoma 5 speed 3.4

Remains to be seen I bought the tires and wheels the rest came along

If it was me I would clean the old rust off as best you can .
Use some Fiberglass Mat call it good about the cheapest Even though I can fabricate I fixed many beds with fiberglass

Weld in some patches but since you don`t weld that could get expensive

Get real lucky and find a rust free bed though you might need to go pretty far south shipping $$

It all depends just what you want to do
Norcal89 Active Member

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Mar 26, 2013

Member:

#100647

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26

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Male

San Francisco

Vehicle:

Black 2003 2.7L Regular Cab 4x4 5 Speed

Having the same issue right now. From what I've read, cutting out and welding a patch is the best option. Currently have flex seal tape over it to prevent any additional water from getting into the metal and dripping under while I find someone to do this rather small job.