Third gen. rust issues

[Mokume]

]

My 2000 SuperCab has rust issues on the roof panel just behind both doors on both the left and right side door openings. I've seen other SuperCabs with the exact same problem, has any other 3rd gen owners experienced the same issue?
My '91 extended cab had no such problem, but that roof structure was entirely different, it had proper rain gutters.
There were other Ford's in the family stable, all of them 1st gen. Panther bodies which experienced rust in the same area and were clearly visible, on my 2000 the rot is only visible with the doors open. A body and fender buddy of mine explained that the roof and side panels were spot welded together and unsealed, allowing moisture to get in there and be trapped on the Panther series.
I sure hope Ford recognized and remedied this problem with the 5G body structure, perhaps Mr. Schilke can elaborate?

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[P. A. Schilke]

]

My 2000 SuperCab has rust issues on the roof panel just behind both doors on both the left and right side door openings. I've seen other SuperCabs with the exact same problem, has any other 3rd gen owners experienced the same issue?
My '91 extended cab had no such problem, but that roof structure was entirely different, it had proper rain gutters.
There were other Ford's in the family stable, all of them 1st gen. Panther bodies which experienced rust in the same area and were clearly visible, on my 2000 the rot is only visible with the doors open. A body and fender buddy of mine explained that the roof and side panels were spot welded together and unsealed, allowing moisture to get in there and be trapped on the Panther series.
I sure hope Ford recognized and remedied this problem with the 5G body structure, perhaps Mr. Schilke can elaborate?

Hi Mokume,

Sorry, I was long retired by the time 5G came out and have no idea what they did or did not do on almost the entire body. I certainly hope the engineers in body engineering used the techniques, tools and materials of the current day for the design.

Best,
Phil Schilke
Ranger Vehicle Engineering
Ford Motor Co. Retired

 

[I_smell_like_diesel]

My '99 SuperCab was a rust bucket after 220k miles/15 years in the Great Lakes Rustbelt. The Bottom of the Doors and seams were pretty much trash. Same with the door sills, near where the two doors meet. Looks like there has been years of moisture build up in the lower weather strip on the picture. Moisture found a way to wick into the seam and started to do what it does best unfortunately.... rotting from the inside out.

In my experience, rust repair on a 20 year old vehicle it to be expected. Once again, In my experience.... It may differ in your area and I'm not trying to say your expectations are unreasonable.

 

[Mokume]

Hi Mokume,

Sorry, I was long retired by the time 5G came out and have no idea what they did or did not do on almost the entire body. I certainly hope the engineers in body engineering used the techniques, tools and materials of the current day for the design.

Best,
Phil Schilke
Ranger Vehicle Engineering
Ford Motor Co. Retired

Thank-You sir for your candid and honest response. I also do hope that the body engineers utilized modern design advances as well
I've no problem with drilling holes in the inner body panels in these areas on my soon to arrive 2020 SuperCab and to apply rust preventative to these areas. Of course these holes would be addressed properly so that they themselves do not cause corrosion.
A well known independent repair shop You Tuber recommends the "Krowne" line of chemicals, although independent research is always prudent.
I'm sure you remember Ziebart rustproofing with their signature yellow body plugs, that coating they applied was messy and you could smell it from a distance.

 

[Mokume]

My '99 SuperCab was a rust bucket after 220k miles/15 years in the Great Lakes Rustbelt. The Bottom of the Doors and seams were pretty much trash. Same with the door sills, near where the two doors meet. Looks like there has been years of moisture build up in the lower weather strip on the picture. Moisture found a way to wick into the seam and started to do what it does best unfortunately.... rotting from the inside out.

In my experience, rust repair on a 20 year old vehicle it to be expected. Once again, In my experience.... It may differ in your area and I'm not trying to say your expectations are unreasonable.

Thank-You sir for your candid and honest opinion as well.
I must agree with you about the weather strip holding moisture and I regrettably was mostly to blame for this situation.
You see this truck spent 14 years on Honolulu's waterfront when I worked as a Marine Engineer on board the fireboat "Moku-Ahi".
Typically I was at this location 10 days out of each month for 24 hour shifts, because of this I would hose down and dry the entire truck when getting off shift in an effort to remove the inevitable salt spray. Believe me, I will be a lot more diligent in drying off these areas after washing the 2020. I've since retired from the fire department, so my the new truck won't be constantly exposed to closeup salt spray.
Luckily the roads do not need to be salted here, but the entire Hawaiian Islands are blessed with salt in the air, so rust on any exposed surface is a problem. I've seen videos of cars from the rust belt, all I can say is OMG.
Love your screen name, I also worked as a fire equipment mechanic and can identify with unintentional diesel showers, sure beats gear oil in your hair by miles though!

 

[I_smell_like_diesel]

Thank-You sir for your candid and honest opinion as well.
I must agree with you about the weather strip holding moisture and I regrettably was mostly to blame for this situation.
You see this truck spent 14 years on Honolulu's waterfront when I worked as a Marine Engineer on board the fireboat "Moku-Ahi".
Typically I was at this location 10 days out of each month for 24 hour shifts, because of this I would hose down and dry the entire truck when getting off shift in an effort to remove the inevitable salt spray. Believe me, I will be a lot more diligent in drying off these areas after washing the 2020. I've since retired from the fire department, so my the new truck won't be constantly exposed to closeup salt spray.
Luckily the roads do not need to be salted here, but the entire Hawaiian Islands are blessed with salt in the air, so rust on any exposed surface is a problem. I've seen videos of cars from the rust belt, all I can say is OMG.
Love your screen name, I also worked as a fire equipment mechanic and can identify with unintentional diesel showers, sure beats gear oil in your hair by miles though!

I've been rebuilding more rear ends that working on diesels lately. Have to bring a change of clothes and shower at the end of my shift, or else everything I rest against and touch will smell like LSD friction modifier . Thanks! And you're welcome sir. Thank you for your service in the fire department.

 

[Mokume]

I've been rebuilding more rear ends that working on diesels lately. Have to bring a change of clothes and shower at the end of my shift, or else everything I rest against and touch will smell like LSD friction modifier . Thanks! And you're welcome sir. Thank you for your service in the fire department.

Thank-You sir, for the very kind remarks.
After 28.5 years with HFD, I've come to realize that it is time to let the young bucks run into burning buildings.
Wishing you the Happiest and Safest holidays.

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