Looking for input on a couple of things.
1. I just got done patching my floor pans, the were rusted through in the front seat foot wells, outboard, where the pans start to turn upward. I was figuring this was due to tracking snow into the vehicle, then it melting and soaking the carpets. After reading some about leaks, I'm not so sure. I don't have sun roofs, I rarely use the AC, and I do not recall ever seeing water standing on top of the floor mats after a rain. The only other thing I can think of is windshield leaks, but I've not seen any indication of that. Any ideas on that?
2. I have been looking for fitted floor mats to contain snow tracked in, but have not found any. The Husky heavy duty mats look to be the best I have found for containing water. Anyone know of anything better?

 

Windshield or sunroof leaks are common. A big one is water running below the windshield and directly into the heater air intake. As for mats, I use the cut to fit ones from Costco. We don’t get Alaska snow here, but I’m in British Columbia’s interior and I ski quite a bit.

 

Thanks for the reply. If water is coming in the heater intake, can it be seen dripping or running inside the vehicle? How about with windshield leaks?
I guess I'll start feeling the carpet after rain to see if it's wet.

 

It drips from the heater, often into the electronics in the passenger footwell.

 

I have seen slightly rusty floors on D2's just from salty snow getting in the vehicle on feet (ie no known water leaks otherwise). So it's possible. But more likely leaks from A pillars, door seals, thru the HVAC air intake, or through body seam sealer down the lower a-pillars or inner fender wells.

 

 

Looks like a proper repair job btw. Good work.

Are you sure that rusted from the inside out? It looks like it may have been debris getting in the seams between the firewall and the fender (inner) from the outside and rock abrasion starting corrosion. Do they use salt in Alaska ? ie -- Maybe it just abraded / corroded from the outside in. How's the rest of the underside look?

If it was from inside out, usually the rusted areas are a bit lower (although that area gets it too).

Have you checked each rear outer seat belt anchor point. They go also... in a similar fashion from the underside in.

 

Thanks Nash.
No, I am not sure that it rusted from the inside out, but it appears that it did to me. The rust didn't look so bad from underneath, and there was not much undercoating missing. I found when I took out the interior and started cleaning that the rust was far worse than it looked like from underneath. The city started using a chemical treatment (salt) about 10 years ago. I would guess this rust started before that. Most of the underside looks pretty good.
I bought the truck around 8 years ago, I think. I was told it had been sitting for 2 years. It seems I might recall that a window or two were not up. Anyway, who know what happened to it before I got it.
I have not checked the seat belt anchor points, I'll do that when I get home. I got the patches in and painted, then I had to leave to go to work. When I get back I plan to apply some undercoat, then leave it sit outside. I'll let it get rained on without the interior in it so I can look for leaks.
I thought I took some pictures of the floors after I painted, but I can't find them on my phone so I guess not. I did get one with my patch sitting next to the hole.

 

Best way I've ever found to check a D2 for leaks. Sprinkle the areas where it could leak with talcum or baby powder or similar (Full disclosure I did this on a ****box and I have no idea if it damages paint so check). Then let it leak ... you will see white trails where anything leaks and dries. Very helpful. I found a leak in the seam sealer where the A pillar meets the firewall this way, that I could not find any other way.

 

I appreciate the input. I figure if I leave the interior out and look at it during over after a rain, I should see water on the floor. If I find water on the floor I'll start looking for the source. If it's dry, I'll figure I don't have any leaks.
On one of my other rigs the floors were rusted out, water was coming in a seam in the cowl and running down the firewall behind and under the mat. There was no indication of a leak with the mat in it.