Repairing Rusted Steps - Step By Step - Tech

...he then followed his markings with a cutting wheel (a plasma cutter could have been used as well).

Along the step seams, there are a series of spot welds roughly every 1 1/2 inches. What remains of the step needs to be removed from the step flanges. Todd started off by drilling a small pilot hole through each of the spot welds.

There are drill bits specifically made for drilling out spot welds, but Todd used a slightly larger drill bit, which works as well.

With the step seams removed from the flanges, the next step was to grind along the flanges, including the middle support bracket. The flanges may be a little bent from removing the spot welds....

...If that's the case, a hammer and dolly can straighten them out.

Another area that needs to be ground down is the bottom corner of the cab where the step meets it.

Here's the Brothers step right out of the box. It comes as one solid piece ready to install, which makes things easy.

For the test fit, Todd placed the Brothers step in position. For the most part, things were pretty close, but he did have to do a little minor bending and trimming, which is typical due to age.

Once things were fitted properly, the top edge of the Brothers step was hammered to fit the edge of the upper step.