How common is this?

[93 W350 LE]

So when I got my truck, you could touch the inner layer of the roof trough holes as big as your hand, on both forward roof corners.
My Dad had the truck repainted and supposedly this was repaird when the holes were much smaller. Was told this was common of these trucks. Really? I have personally owned several trucks through this body style, and never experienced this.
Any ideas?

Thanks.

Eric

[ellis93]

I don't know how common your issue is,but my truck is rusting from the inside out of the roof right along the rail. I've fixed it a time or two by welding the holes up but this winter the roof is coming off

[dazedandconfused]

Check the seem sealer in the drip rail. I'll bet the edge the windshield sets in is rotted as well. My old cab was like that. Water was getting in between the skins and rotted the bottom out.

[93 W350 LE]

Started to try to stop it his weekend. Digging out the old sealer, digging out all the old rust I can get to in the roof, layed some metal mesh and fiberglass, now have to do some bondo and redo the seam sealer. All while driving daily in SWFla's rainy season, so rain everyday. UGH!
Any suggestions for repairing this, or is it just band aid until I find another cab?

[dazedandconfused]

I'd personally look for another cab if its as bad as you say it is.

[93 W350 LE]

Yeah, I can lay an open hand in each side at the largest part. It involves both outboard marker light at their outside screw holes. The sad thing is the rest of the truck is solid.
Anyone know what a club cab is runnin these days?

Thanks.

Eric

[dazedandconfused]

Seen a few rust free ones from $800-1000 but they are out west.

[93 W350 LE]

I need to check with a friend back in Oklahoma who owns a Dodge/Chrysler salvage yard. Would like to do a swap to an old crew cab, with having 2 little ones it would be nice.


Eric

[93 W350 LE]

So I gutted the drip rail of all the old seam sealer, wire wheeled it, got all the old rust out I could get to. Used aluminum grill grate to shape and applied bondo, reapplied seam sealer and sanded and primed. Looks pretty good, and the last few rains haven't soaked my floor or had water run down my pillars. Now to get new marker lights and refinish the rest of the roof.


Eric