Rust in floor pan weatherstrip channel

[i82much]

My truck (72 k10 longbed) isn’t so bad from a rust standpoint but the channel on the floorpan where the door weatherstripping goes is pretty rough. Looks like debris fell down into that channel and collected moisture. Is this a common issue or do people usually have trouble with the whole floor pan? Is there a simple repair technique for this issue?

I was thinking about just welding a strip of metal in underneath the channel, I doubt there is a specific patch panel for this area. Is that an acceptable repair, or is there a better approach?

[Richard]

The flange that sticks up is part of the outer rocker. What I think you call the channel is part of the floor/inner rocker. The patches you would need will be on the inner rocker patch and outer rocker patch. You can see what I did in my thread.

[i82much]

thanks richard!

[sick472]

If the rust through is just at the channel and does not get outside it into the rockers, some light sheet metal angle could be used to repair just that area. My driver's side channel is now part Frigidaire. I happened to have an old fridge that donated the strips of angle needed to rebuild the channel. I cut a length of the corner of the outer skin to create the needed pieces. It's a little time consuming, but, back then...my time was free and my budget was nil.

[May70]

Show us a picture please

[i82much]

Originally Posted by May70

Show us a picture please

Pic attached! The rust seems to be pretty concentrated in this channel. There was a bunch of debris in the channel when I got the truck, almost like the truck had missing weatherstrip for years. The surrounding areas look pretty solid.

[May70]

Looks like you need a new outer rocker and probably repair some spots on the inner. Ive got some videos on the process.

[i82much]

Originally Posted by May70

Looks like you need a new outer rocker and probably repair some spots on the inner. Ive got some videos on the process.

Nice videos, thanks!

Let's say you were using the truck to plow snow for the next five years or so and do not foresee an opportunity to replace the outer rocker. Is there a short-term repair worth considering, or just keep plowing snow and do it right when you are ready to dive in headfirst?

[May70]

Bowie doesn't get much snow (if any lol), waiting a few months isnt going to drastically change anything unless you are very rough on your truck. If you really hustled you could do inner and outer rocker in a weekend.

That spot will get drastically worse and turn into a totally rotted inner/outer and probably eat your pillars.

Early is always better than later

[i82much]

Originally Posted by May70

Bowie doesn't get much snow (if any lol), waiting a few months isnt going to drastically change anything unless you are very rough on your truck. If you really hustled you could do inner and outer rocker in a weekend.

That spot will get drastically worse and turn into a totally rotted inner/outer and probably eat your pillars.

Early is always better than later

I need to update my profile, I'm in Spokane now! It's been that way for years, but Spokane is actually pretty dry most of the year. I'm sure it would be a lot worse back east!

[May70]

Originally Posted by i82much

I need to update my profile, I'm in Spokane now! It's been that way for years, but Spokane is actually pretty dry most of the year. I'm sure it would be a lot worse back east!

Talk about relocating haha.

If its just the top that is bad you could try just cutting out the top section of your rocker and any needed on the inner and replacing it that way vs taking it off entirely. Problem is you will likely have issues in there when you open it up.

[sick472]

It's always hard to tell what's "back in there" until you start drilling and cutting. With that said, all you can do to try and slow it down is to clean up what you can get at, put the primer and paint to it thick and heavy, shield it from the elements, and wash it and flush it after wet nasty uses.

If I were wanting to spend a day or two trying to preserve what you have...I would consider sand blasting all the visible rust, coating with a self etching or epoxy primer, and painting it well with an engine enamel or the like. Get new door seals on it too if they are to blame and some mud flaps up front.

[i82much]

Yeah I tried cleaning out the channel and squirting some fluid film in there. I don't think it's rusting much more now, I just kind of feel weird seeing the ground through the floor like that. I guess I really ought to pull it into the shop and see what else I've got going on before I decide what to do next.

I have a 2016 2500HD that is my daily and can plow the driveway just fine. But I like to put the chains and plow on in November and take them off in March, and if I do that with the 2500HD I can't daily drive it.

I guess I really need to decide whether I want to fix my 72 or plow with it first! Or do what I can from March-October without taking it apart so far I can't get it back together before plow season.