For the frame, check into Hot Dip Galvanizing...you can do a search. You will need to do all of your frame mods, add ons, suspension changes prior to the HDG process. Welding onto Zinc-ed metal is not healthy. I have about $125 in initial sandblasting. A friend at the HDG plant got it done for very cheap, but should be in the $200-300 range for dipping. I would recommend having it powder coated afterward. I have had some adhesion problems with my paint system, even though it was prepped properly and an appropriate paitn system was used. Either way, the frame will not rust again...at least not for 20-40 years. The paint was only for aesthetics. All in all I have about $500 in getting the frame done, probably less, but that would be the normal price if you were a guy off the street (I am factoring in my travel costs--trailer rental, gas, etc--to transport it 2 states away to have it done).
Tub, paint and body:
I did all of my body/rust repair- which wasnt alot--much less than many/most--new front floors, some inner rocker and door post fixes. I then had it silica and or soda-blasted--depends on the individual part ($850 for tub, doors, hood, tailgate, grill and dash). Turned out beautiful. Keep in mind this was all done on a loaned rotisserie and yes, I did brace my doors.
Paint and Line-X: I will roll this into 1 cost. ...also, still on rotisserie-much easier to deal with. As I think it about evens out whether you paint the entire thing or go paint and Line-X. I had the paint shop prep, do the fine-fixes that I could not do-mostly metal work, very minimal filler, quench the entire lot with metal conditioner, etch-prime, paint (base coat/clear coat with Dupont Chroma Premier= lifetime warranty on finish and rust, since it was all done "right") the doors, hood, rear quarters, grill, dash. Then, it went to Line-X where they lined -in black- the entire underneath including rear wheel wells, the engine compartment from just below the hinge-mounts for the hood, the cowl and entire front clip, the inside from the break at the top of the dash down the entire inside of the tub out over the rockers to the bottom, up and over the bed rails. The tailgate lines match the bed and the liner coats the inside face of the tailgate around to the sunk-in face of the tailgate. The rear quarter matches this tailgate line, but only goes as high as the door on the rest of the rocker. They also Line-X ed my inner fenders on the fronts and the inside (removable) door panel inserts (front and back. It all looks fantastic. I have about $4400 in the paint and Line-X...which I think is pretty reasonable. This does not include any work on the hardtop...which I will do the same process with this fall...inside and out in black line-X...sound, rust and scratch protection. There are a myriad of unseen costs, expenses and headaches along the way...and these are not mentioned here. The numbers above are only the "sub-contracted amounts paid to the 3 shops (media blast, paint and line-x shops). I still have months of work to get this thing "finished" or at least back on the road. Whatever you think it will cost...multiply it by 2, take a deep breath--once you have your breath back, divide that number by 2 and then re-multiply by 3 and you will be close.
You asked!...just trying to give you an idea on what I thought was "doing it RIGHT". I could have spent more on the paint-work, but the shop I used is new, hungry and they really liked the product so they gave me a great deal on my per-hour labor rate, which save me about 20-25% alone. In reality there is no need to go too crazy on paint, where the Line-X will be covering it...you only have to make sure it is rust free and properly prepped for good adgesion. Lots of details to consider when Line-X-ing so much of the tub...lots of potential fitment issues. The work the paintshop did was/is fantastic...however it isnt 'show quality", but it has so far exceeded my expectations and would be darn close to that level of qual. Besides, this will be a GO pony, not a SHOW pony. Hopefully, I can keep it ding and dent free for at least a year...yeah right.
HTH!
