Repairing Rusted Steps - Step By Step - Tech

With things lining up correctly, the edges of the steps were ground down to the bare metal.

What holds the majority of the step to the flange are plug welds. Todd started off by drilling pilot holes about every 3 inches along the edges of the new step....

...He then returned with a 7/16-inch drill bit and opened up the holes.

The step also gets plug-welded to the center support bracket. Therefore, Todd also drilled holes in the middle of the step.

Next, Todd lined up the rear of the step with the cab and clamped it into place. This area has to be welded in and then finished off, but not quite yet. As for the rest of the step, Todd used roughly 6 self-taping screws to hold the step in place while he began plug- elding.

Using an MIG welder, each one of the holes drilled previously was plugged up. For added strength, Todd stitched the seam with a weld about every 5 inches.

With the step held in place, the rear corner was welded up.

Lastly, a grinder ground the plug and stitch welds smooth.

Voil! The new step is installed. Now all that's left is finish work.