Not sure if it's been said yet, but if it hails where you are check the roof. Hail might have chipped away some paint and could rust.

 

I just put this in the other rust thread, but why not share this gem again?

 

^^^^HOLY! how could you let it get that bad?!

OP, i'd check rockers, insides of both bumpers, and gas cap area. and your frame will obviously have some surface rust too (at least up north)

 

Haaha, it's not mine. This started about 2 years ago on my buddy's truck. This truck was some kind of experiment by ford. 04 FX4 with all kinds of problems that ford techs look at and shake their heads. There is some kind of sound deadening stick on deal that holds water behind the paint, so it has rusted out from the inside. It doesn't even pay for him to fix it, because the whole inside of the bedside is rusty, it's Fckd and he is looking for a whole new bed. ALong with all kinds of front end problems, he brought his truck over for a simple U-joint change, which turned into him getting a new driveshaft because of the cups that you have to grind out to get the old ones off. What a joke. I would have put a brick on the pedal and sent it through the ford headquarters, but he has a little bit of a cooler head than me. He loves it when we call his 2004 truck a piece of antique farm machinery.

 

My truck spent the first 4.5 years of its life in Ohio, and basically the entire underside shows signs of rust/oxidation from all the salt they use on the roads.

Its a tough battle, I sprayed a tar sealer type deal in my wheel wells, and washed it often with applications of rust inhibitors and it is still a losing battle.

Now that I have the truck in down here in florida and it isnt being used as a work truck anymore, i am going to really concentrate on getting it cleaned up top to bottom inside and out.

 

My 08 is chipping and starting to rust on the rockers where the stepbar mounts are. Most pick up's rust there,my GM's had the same issues in the same spot.Bring it to Line X and have them clean and spray the rockers and you'll never have an issue in that spot anymore,im doing mine as soon as my tax refund gets here,also oil it EVERY fall esp in rust belt areas.

 

Just bought a 2007, and had to do some paintrepair on the rear lip of the box, hidden by the tailgate. I stripped it down and repainted it, and it should last for as long as I keep it (probably at least another 10 years befor I get the urge...)

 

Has anyone ever heard of filling their can corners in with expandable foam to prevent water from getting in there?

 

It might work, but if water/salt does get in behind it I think that it will be twice as bad.

 

Kinda what I was thinking