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Posted by Keith in Washington [24.41.41.111] on Friday, January 01, 2010 at 22:39:12 :
In Reply to: Carryall metal thickness posted by Tim [70.185.103.10] on Friday, January 01, 2010 at 18:31:46 :
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The reason it rusted out was that the inner and outer skins were bent and spot welded together forming a closed structure. That is OK if you do not have any water in it. However, the window box directly above it has a drain tube that empties into that space. When I patched the inner and outer skins I did not fully enclose the area. I left over 1/3 of the bottom open so it would quickly drain. You will never see the openings as the running board covers that area preventing both visually seeing it and blocking any road spray up into the area.
Also I removed all of the window boxes and repaired them as needed. Be sure to remove and kill all rust and then paint the inside of the outer skin behind the window boxes. There is always a lot of rust in that area and on the back side of the window boxes as they were never painted at the factory.