taking the torque box apart
Taking the torque box apart was a good idea. In my project update you can see the box installed now. It fits pretty well and both joints inherent to the box are better now for it.
I'll take your advice on filling the gaps with a good sealer as well. The problem with the original set up is that there are holes that allow dirt and debris to fill up any cavity that is not plugged up. This material holds moisture which in the end is death to what ever it is exposed to. It's like holding a wet sponge on the material indefinitely. It doesn't take long in that kind of environment for rust through.
I've got some touch up to do on the floor interior but for the most part I'm done with this side. This week I'll work on the passenger side floor and torque box. It looks to be in better shape and I'm counting on less trouble. (That'll probably jinx er right there)