Rust Free? Really?

[Blue68]

So I got the outer rockers off. Body shop buddy of mine strongly suggested NOT drilling out the welds (followed his advice since a) he does it for a living and 2) he'll be welding on the new parts). Besides not being able to find most of them and several being rotted through, it takes off good metal on the inner rocker (which will have to be replaced anyway...hmm waste of grinder time?).

When I got the outer off, I started prowling around. Here I thought I had rusty rockers and kick panels. But the hole THROUGH the lower part of the front pillar told me otherwise.

So, besides what effort is required to replace this (I know about patch parts from Goodmark) in regards to bracing when cutting out the old, is there really such animals as rust free cabs? Or just rust free as far as you can see?

I really though my rust was not quite this bad. Not a big deal, just a little dissapointing.

[Hutch]

The main area that I have seen rust in these cabs is due to the drip rail sealer getting old and cracked which alows water through or along the windshield down the cowl to the inside of the cab amd on to the rockers. When you have the winshield out this area becomes rather obvious. Needles to say special care need to be taken to ensure no leaks in the future. Gravity plays a major role in this event.
In order for a cab to be rust free it would have had to been stored inside or in a very dry climate.

Some feel that these trucks could have been constructed better and used better materials. You have to remember that these trucks did not cost alot compared to todays prices when new and they didn't plan on them staying around for 30 years.