Recreational Vans

Rust inspection for vans and trucks

Rust inspection of a van frame and undercarriage on a lift

Why rust happens and where it hides

Rust forms when steel meets oxygen and moisture, accelerating in the presence of road salt and temperature swings. Vehicles trap water in pinch seams, behind plastic liners, and inside boxed sections where airflow is poor. Common hot spots include frame rails, crossmembers, rocker panels, wheel arches, roof gutters, sliding door tracks, and the lower edges of doors. Brake and fuel lines, especially where clips hold them to the body, can corrode out of view. Even seam sealer can crack over time, letting salt laden water creep into joints and start corrosion from the inside out.

How to perform a thorough rust inspection

Start with a clean vehicle. Wash the undercarriage and wheel wells, then let it dry so moisture does not mask corrosion. Use a bright flashlight, inspection mirror or borescope, a small pick, and a magnet. Look along wheel arch lips, rocker pinch welds, roof gutters, around the windshield and rear windows, and under trim pieces that catch debris. Underneath, check frame rails, crossmembers, spring perches, control arm mounts, skid plate mounts, exhaust hangers, and the floor pan. Probe flaky layers to see if scaling is superficial or if it collapses into soft metal. Follow brake and fuel lines end to end, and inspect heat shields and fasteners around the exhaust where condensation accelerates corrosion.

Severity levels and what they mean

Surface rust: A thin orange or brown film that has not pitted the metal. It can often be cleaned, treated, and primed without section replacement.
Scale rust: Flaking layers where thickness has reduced. This weakens metal and often requires grinding, patching, or panel replacement.
Perforation: Holes through the panel or frame section. This indicates serious deterioration and typically requires cutting and welding.
Structural compromise: Corrosion at suspension attachment points, steering components, or frame sections that support loads. This can be unsafe to drive until repaired.

Repair paths, protection, and cost signals

For light oxidation, wire brush to clean, apply a rust converter, then use zinc rich primer, paint, and a topcoat or cavity wax. For scale, plan to remove unstable metal and rebuild with welded patches or replacement panels. When frame sections are affected, a certified welder should plate or replace compromised areas and verify alignment. Use caution with generic undercoating on active rust, as it can trap moisture; treat and seal first, then protect. Cavity wax inside boxed rails, seam sealer in repaired joints, and stainless hardware where appropriate help slow future corrosion. Costs rise with hidden decay, panel complexity, and the need to drop fuel tanks or remove interiors to access floor sections.

Safety critical zones to prioritize

Brake lines and fuel lines
Suspension and steering mounts
Seat belt anchors and seat bases
Battery trays and ground points
Jack points and pinch welds that support lifting

Prepurchase and seasonal inspection tips

When considering a used van or truck, scan for inconsistent undercoating, fresh paint fogging on hardware, or missing seam sealer that might hide prior rust. Pull back cargo area mats to check floor pan seams. Open sliding doors and look at lower track areas and drains. In snow belt regions, plan for a spring inspection to address winter salt buildup and a fall inspection to prepare for the season. Rinse the undercarriage after beach driving or salty roads, and keep drain holes in rockers and doors clear so water can escape.

Integrating rust inspection into upfit planning

A rust inspection is more than a safety check; it shapes smart decisions about upgrades. If a frame crossmember is scaling, address it before adding weight or suspension changes. If the roof gutter shows bubbling at the seam, repair and seal before adding a rack. Treat floor pan seams before installing cabinetry to prevent trapped moisture. Transparent documentation with photos and measurements creates a baseline for future reference and protects resale value.

How OZK Customs approaches rust during builds and upfits

Before we design cabinetry, power systems, or exterior armor, we assess the vehicle’s condition so the foundation is sound. Our team inspects frames, floor pans, and load bearing points, then documents findings and recommended fixes. When metal replacement or bracket fabrication is needed, precise fitment and corrosion minded finishing are built into the plan. After repairs, we select protective coatings, seam sealing, and cavity wax for long term durability that supports life on the road. This approach keeps adventures focused on the trail ahead rather than chasing rust after the fact.

Ready for a professional assessment and plan

If you want a capable road partner, start with a clean bill of health. We fold rust inspection into our build intake and upgrade planning so your rig is safe, quiet, and ready for the miles. Explore how we craft capable travel platforms, from layouts to protection, and see how a methodical inspection sets the stage for a long running vehicle.

Tell us about your vehicle, where you drive, and any rust concerns you have noticed. We will evaluate structural points, document corrosion, and map a repair and protection plan that supports your future build or upgrades. Submit the form to start your rust inspection conversation with OZK Customs.