Quote Originally Posted by ipd View Post
VERY difficult for rust to form/expand when it's sealed virtually airtight with insulating foam.
I agree, but discovered this on my own, and it took about five years to figure it out.

http://forums.pelicanparts.com/off-t...-up-epoxy.html





So seven years ago both sides of the S10 lower cab corners had rust. The worst side is show above and had expanding foam as a backer. The other side had much smaller rust holes and did not require the foam backing.

Five years after the fix the side with the foam backing still looked good, the other side was totally shot.

These last two years have been rough, now both sides are gone...............but it looked good for five.

When I initially did this work I was fearful that the foam would absorb and lock-in moisture. I expressed by concern on-line in a S-10 forum seeking some opinions of people with similar experiences and some snot nosed punk starting calling me names because of what I did. Turns out the thing I feared was in fact the better procedure.

I would think that filling your frame rails is a good idea, just hope you never have to weld anything to the frame.

If one were to fill most of their interior body panels with foam, I bet it would help in a crash as well. Getting all the door hardware to work might be problematic though.