Rocker Panel Rust: Looking for advice on best product/procedue

This spring/summer my plan is to do any maintanence and rust repair/prevention needed to keep my "new to me" 2006 DCSB on the road up here in salty central NY as long as possible.

The truck came with a new frame so my plan there is to do Eastwood internal frame coating then FF the whole thing really well.

I bought the truck knowing it had some rocker panel rust but also know I can handle it.

I plan to take out the plugs on the rocker panels and FF in there but first want to take care of the mild rust going on at the pinch joint.

I'm thinking sand/wire wheel rust, then Eastwood Rust Encapsulator. Next paint and clear coat.

I also saw they have a rubberized Encapsulator but not sure how it will hold up.

There is also some mild rust in the engine bay, figuring on doing the same process in there.

My questions are:
Am I missing anything, or going overkill?
Any thoughts on the rubberized Encapsulator?
Any experience or pro tips? (Not to many threads on taking on rocker panel rust).

I'd like to make as few orders as possible so I'm trying to get all my materials lined up and then not have to reorder anything once I get started.

Pics for reference:

 

I also live in NY so have the same issues. I haven't yet tackled the inside of the engine bay but I removed rust on the inside door sill and rocker panels. You can use sandpaper but wire brush on a drill is probably best for door sill. I removed rust completely down to metal then primer n color matched paint. If u blend it well it's not noticeable.
Places where there is a lot of rust u can use angle grinder but be careful if it's in a tightimely place so you don't grind smth accidentally
I want to do some areas in my engine bay but haven't because space is super tight. Not quite sure how I would reach some places and worried about chunks falling into alternator etc

 

That's rusting from the inside out. Nothing you do to the outside will stop it.

 

Keen observation.

That's why the FF inside the rocker panels is a must. Also going inside the wheel wells too.

Metal up here is going to rust, can't stop it, but I plan to keep up with it.

 

Uhh, Fluid Film aint gonna do shit to stop the rust that's already INSIDE your rockers.

 

So any suggestion?

From what I hear FF is pretty good at stopping rust, but maybe an Eastwood product in an aerosol can would be better?

 

The fluid film might slow it down a bit, but you're probably only buying a year or so. Rust is like cancer.

I've cut out and welded in new rockers on Chevys before, but never on a Toyota.

Replacing the rockers is really your only option.


For anyone else reading this, take the rubber plugs out of your rockers and spray the crap out of the inside with fluid film until it's running out the seam on the bottom of the rockers and you won't be in this situation.

 

I guess I'll just work to slow it down until I got to replace them. Thanks for the insight!

 

I would pull the plastic plugs on the bottom of the rockers and then source a rust encapsulator and spray inside best you can. It may slow it down for awhile but they will rust through. My old 4Runner was the same way,rockers were perfect but you could see perforation on the seams. 2yrs after I sold it to a buddy the rockers are rusting through.

 

You would have to cut it all out to fix it, nothing else is really going to help.

 

To prevent future rust instead of fluid film you can get it professionally coated with Krown rust protection. They have the ability to get everywhere fluid film cannot. Door internals, sills, hood, wheel wells from the taillights, tail gate, engine bay, rocker panels and every crevice of the underbody. I'm near Watertown and I've had it done because the salt is bad up here too.

 

Don't overreact, it's just starting to rust. Sandblasting and good primer/paint, fluidfilm inside and many rustfree years to come.

 

FF will definitely slow down established rust. So will keeping your truck dry and salt free. I run a dehumidifier in my garage in fall, winter and spring. I did not know how much that helps but you can't stand by and watch rust take over haha. Having said that your truck looks pretty good for a 2006! If I get that much out of my 2015 living in a snow belt in central Ontario I'll be happy. some of the rust in the photos looks like paint failure, so sanding it off and recoating it with something tough will help for sure. If you colour match the final coat and set a pro standard for your work, it will look good even if it's temporary.

 

Luckily I never expected a rust free truck in the salt belt!

I'm thinking spraying a rust Encapsulator in the plug holes and then a good sand/paint job plus FF will be my best bet.

 

Need to knock rust off with sand blaster or needle gun. You can grind but wont get all the rust scales . Don't be surprised to find holes in metal .

 

Thanks for the tip. I'll be looking into a needle scaler. Went out and did another look at the rust, doesn't look deep. I think it will clean up fine and also I pretty confident that I can "stop" the rust inside the rockers.

Worst case I postpone cutting and replacing for a couple years!

 

Went out and did another look at the rust, doesn't look deep. I think it will clean up fine and also I pretty confident that I can "stop" the rust inside the rockers.

Sometimes after using needle gun surprising how deep rust scales are .Yea hopefully will be alright .good luck . Rust sucks......

 

Every year, I spray about a whole can of WD 40 in the weep holes in the pinch seam of my rockers. I've done this on my old T-100 for years. It's a 1998 and the rockers and cab corners are still solid. I am getting some rust on the bottom of the doors now so I'll have to hit those on my Taco going forward.
We live in southern Illinois so no where near as bad for salt around here but I think its time well spent. I would think Fluid Film would be good but not sure how well it wicks into small cracks and crevices. WD may not be the best but it's better than nothing. I think you're on the right track.

 

https://www.tacomaworld.com/threads/rust-prevention-treatment-consolidation-thread.355928/