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So during lunch I took a look at my coolant level and it has now gone down below the full cold line. It took 3 weeks of daily driving since the manifold reseal. Here I hoped the crack in the block was superficial and the coolant use would stop with any luck. It doesn't look that way tho so another motor is still on the list. Well It was anyway but I kind of glossed over it. Kinda got me down on the whole project.
So I cried a sob story about it to the wife and she told me to go out and buy a $30,000+ truck and have that rust out in 5 years even if I wash it like the neighbors truck. She asked if that was in the budget??? In other words she said "Suck it up buttercup and keep building!" I love that woman!! Like when I told her my engine was doomed she said "Now you get to buy one you want or build a HOT one if you like"!!!
I think one of the biggest issues with not only these trucks but a lot of trucks from the GMT400 era was not only that channel but the fact they would put screws right through the sheet metal do a piss poor job in protecting it. Then you get moisture all god knows what else up there causing grief.
The rust tha MUST be stopped! This seems to me to be the most vulnerable spot on these cabs. On the last cab I repired I eliminated this channel. Mot sure yet what I will do on this one. If I keep the channel I will have to check on it at least once a year to keep it from rotting for sure. I wish GM would have done this different.