Rusty Floors

[jskerm]

Did a bit of a backyard blitz on my rusty floors last weekend and thought I would post a few photos. I strongly advise any owners of early range rovers or discos to lift the front floor mats and have a look. I was quoted about 500 bucks to do this job through the local body shop but was quite chuffed to get out of it for less than 50 doing it myself. Not sure it will win any awards but I dont have rust in the floors anymore so its all good.



This is what I found when I lifted the mats

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Quick hit with the wire wheel

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Cut out the bad stuff (1 mm disc is good for this)

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Whip up a template from an old bit of cardboard.

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Replicate it in steel

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Bend to shape

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Prime cut edges and line with body caulking compound

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Stick the pre primed / bent bit of steel in place and rivet / weld ( I chose to rivet as the panel I removed was mostly riveted in place.

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Add a final coat of dulux overhaul and Bob's you're uncle

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I also repainted the outside with body deadener to protect it from stones etc but forgot to photograph

As I said, won't win any awards but an easy backyard solution to a common problem.
Now to refit the carpet (minus the moisture holding underlay)

[Distortion]

I was in the process of doing exactly the same thing to mine
I've had it stored undercover for the passed year so I haven't notice anything but with the recent rain in perth and having just moved I got that nasty wet carpet smell and went looking

looks like some time in passed 25 months rust has broken out in my foot wells anyway I had a good poke at it was a screw driver in the worse looking places and didn't go through so I'm hoping I've caught it in time to avoid patching( I'll put some pics up tommrow once it's light.)

anyway swept and dried in and put some ranex on it which I'll leave over night but I'm think I'll need to get the wire brush out and clean it up properly

Anyone got opinions on wether or not I should go with rust converter + + something like KBS Rust seal(i've had some luck with this in the passed in other vehicles) or cut the floor out and use fresh metal.

I'm also ditching the exising floor lining but would like some kind of soundproofing i'm undersided on the carpet prefer to keep it as it would look better than a patched up floor. I was thinking about getting a rubber mat that won't absorb water and using that instead but I'm still worried about it traping water underneith. Anyone have any other suggestions

[SimonM]

Great job mate. I had mine done professionally and got stung big time but it looks like they did a good job. If there si a next time I would probably give it a go myself.

Since then I have taken out the water retaining sponge underlay and just left in the carpet. Makes it easier for me to check for any water leaks now ;).

[Skiboy]

Guys

Great tutorial - would have benefited form this when I did mine so well done.

Have the same issue and done same treatments.

My issue now is where does the water get in? If we can fix the ingress then will no linger have to fix the effect. Mine is on the divers side and every time it rains water seeps in. I want to stop this but cant see and obvious cause - is it at the roof and in via the pillar, or somewhere else?

Any ideas anyone?

Skiboy

[Distortion]

Anyone know if the plastic plugs/gromets should be kept
seems to be 3 each side I'm trying to decide if i should just fill the holes with gloop and paint it up or keep the plugs

My concern is as I've take off the mud flaps at the front the tyres are throwint water straight at these plugs and thats where it's getting in I don't have aircon functioning any more and no sun roof I've pointed a hose at the windscreen and roof and not had any water get in some might have gotten in passed the door seals but given the location of rust and where the foam underlay was wet this seems unlikely to be the cause.

But the rust itself is coming good was no where near as bad as I thought it was I've ground the worst off and hit the remainder with a rust converter which seems to be working well

Other photos (http://distortion.iinet.net.au/index.php'dir=4x4%2FRepairs)

For now some photos

Drivers side(you can see the holes)
http://distortion.iinet.net.au/pictures/4x4/Repairs/IMAG0076.jpg

Passengers side
http://distortion.iinet.net.au/pictures/4x4/Repairs/IMAG0071.jpg


The plastic plug i'm refering to

http://distortion.iinet.net.au/pictures/4x4/Repairs/IMAG0073.jpg

[Skiboy]

I would be tempted to rivet or bolt a plat over the hole with sealer underneath.

Plugs only allow you to drain the car if gets full of water.

Skiboy