Avoiding hat channel rust

[Bretto]

In an attempt to prevent any rust inside, what would you guys suggest doing before welding on new hat channels? Im not using any wood inserts and they are 16 gage. My thoughts are paint the inside of the channel and the strip where it covers the bottom of the floor with primer but what do I do where the flat surfaces meet where my plug welds go? I can't put regular primer there. Can you use that weld thru stuff and how well does it work?
Thanks.

[wesk]

The weldable primer is the only answer and will survive about 90%. You will never protect all the hat channel from rust after welding. More important when leaving the wood out is welding in steel bushings to prevent the crushing of the hat channel at the bolt points.

Try to keep in mind that the wood reinforced hat channels lasted over 50 years in all but the most abused M38's and M38A1's. Thus a stock wood filled hat channel resto would last a lot more since the use of the jeep after restoration will be a lot softer then the jeep's first 50 years.

[Bretto]

Ya I placed bushings in the bolt points. I figure with 16 gage floors and hat, it will be stiff enough and no wood will be needed. Thanks Wes. Now where to find weldable primer.

[DaveM38A1]

I have used the weldable primer on mine. The 3M brand was more expensive but failed to spray out of the can on more spray cans.
The no name brand in spray cans worked best. You can get it at any auto paint supply store auto parts place. I have seen it at WalMart also.
Last time I did a lot of welding, I got a quart of Rust Oleum weld through primer from Manhattan Supply Company. I brushed it on thick and let it dry, then spot welded the hat channels on where I punched holes. Weld through primer gives good protection because it is high in zinc. The Rust Oleum stuff may have been called cold galvanizing compound and contained 95% zinc.
The only draw back is it is not very abrasion resistant, so don't use it where wear is a factor.

Good luck,
Dave