Expanding Foam - Aaaaaaargh!

[Jim McCrae]

I took off the kick panel on my Traveller to investigate corrosion in the lower sill and discovered that a previous owner has filled the sill with expanding foam. It appears that the foam has prevented drainage and held water against the sill causing the corrosion. What a mess!

https://imgbox.com/LPEErWWU

[rocco]

I imagine the foam was used to cure a rattle. Doesn't seem like a terrible idea on the surface but only if using the car in fair/dry weather.

Did you only take one side off? Might be nasties under the other sill too

[Jim McCrae]

I suspect someone thought that foam would seal out moisture but it seems it actually trapped it.
I have only explored one side so far but I will tackle the other later.

[myoldjalopy]

Goodness knows what they thought - it does seem a crazy idea!

[kevin s]

it used to be done by OEM's to prevent noise (imagine an open box member with a few holes in it is a bit like an organ pipe),that would have been after ecoat though and I can't imagine it will have any benefit on a minor.