HVAC drain and frame rot.

[Clone TIE Pilot]

My otherwise rust free 1987 Regal has some frame rot around the number 2 passenger side body mount. After taking the fender off and lifting that corner of the body up to gain clearnce to weld in a repair washer, I figured out why it rotted. I already wrote another thread talking about how the OEN GM bushing have metal inserts that are prone to rusting out and taking the frame with them. However all the other bushings were no where near as rusted out as the passenger side number 2 was. I figured out why the number 2 mount was so much worse than the other mounts. Turns out the water drain on the bottom of the HVAC box drains water right on the number 2 passenger side body mount, causing it to rust out much more than the other mounts, even the number 6 behind the rear wheels. Some will get sore again at me for saying this, but the HVAC drain is a design flaw, it should not have been placed right over the frame. So besides welding in a repair washer, I need to figure out a way to divert the HVAC drain water away from the number 2 mount, to help prevent this problem from happening again. After looking around online, it seems the number 2 passenger side body mount are the first to rust out, and this is probably the reason why it is so common.

 

[GuysMonteSS]

I would be interested to see what you come up with to divert water away from # 2 passenger side body mount.
I replaced the body bushings in my Monte last year and had to weld in a couple of washers.I think that may have been one of them...
Guy

 

[hurst1979olds]

When I removed my original box for an A/C delete panel I had noticed I had noticed the drain went to the mount but I guess "luckily" my drain was plugged.which would cause water to go in the car. It would fill up the passenger side floor pan...which when rottedout goes to the ground. Or with new pans goes past the seat belt holes.

 

[Clone TIE Pilot]

One thing I am thinking about is to weld the washer on top of the frame, so the mount bushing will be sitting above the puddle. In stock form, that part of the frame is depressed allowing water to pool up in the body mount area. Maybe even drill a small drain hole there?

 

[pencero]

can't you just make a small plastic / rubber tray of some sort to solve this problem?

 

[Clone TIE Pilot]

I am looking into that as well. However the area around the number 2 mount is a depression that collects water. There really should have been a slight slope or drainage of some kind put into the design.

 

[Clone TIE Pilot]

To help prevent future problems at the right #2 frame mount, I used lip type house weatherstripping tape to act as a gutter for the HAVC box drain. This way most of the rain water is dumped over the ground instead of on the frame itself.