Rust

[OlliesLRover]

Disco 1994 V8i Auto.

Decided to replace the carpet strip in the back of the Diso, so I took out the carpet and underlay so I could give the floor a good clean and check for any rust ect.

It appears I am about 10yrs to late (see pic), but in my defence I have only just bought it.

Any way I have decided it will cost tooooo much to get it fixed properly, so am going to get some fly screen wire or similar, and overlap the edges and stuff it into the gap and just bog it after I clean up the rust as best as possible.

Need suggestions on the best bog to get for the job, something that has a bit of flex in it but at the same time will stick the mesh to the floor to keep water from coming up from the ground, I am not overly concerned what it looks like as the underlay & carpet will cover it.

Have checked underneath and that section of the floor sits on 2 solid metal bands that are attached to the chassis above the fuel tank, so it is not likely to collapse, and I don't carry heavy stuff in the back plus I use my other vehicle to carry the wife and grand kids around.

Regards
Rich

[flyreels]

Don't bog it, get a cheap fiberglass kit and fiberglass it, way better option.
Cheers Peter

[Landover]

If you have that much rust there I would be lifting the front carpet and checking the floor in the foot wells. This is another common rust spot as once the underlay is wet it takes a long time to dry out. Also check around the Alpine windows.

The water is probably coming in from the top of the rear door as it does not seal very well. Spray around with a hose and see where it is coming from.

As said Fibre Glass would give a better finish and easier to use.

[OlliesLRover]

Don't bog it, get a cheap fiberglass kit and fiberglass it, way better option.
Cheers Peter

Thanks mate, fibreglass kit it is.

Does the area need to be primed/rust proofed after doing the fibreglassing.

Regards
Rich

[OlliesLRover]

If you have that much rust there I would be lifting the front carpet and checking the floor in the foot wells. This is another common rust spot as once the underlay is wet it takes a long time to dry out. Also check around the Alpine windows.

The water is probably coming in from the top of the rear door as it does not seal very well. Spray around with a hose and see where it is coming from.

As said Fibre Glass would give a better finish and easier to use.

The alpine windows have a bit of rust but have not checked the the front foot wells yet (dreading the thought).

I noticed that the black trim above the rear door is cracked so will get some black sealant and repair that and will get the hose out as well.

Many thanks

Rich

[flyreels]

Thanks mate, fibreglass kit it is.

Does the area need to be primed/rust proofed after doing the fibreglassing.

Regards
Rich

Hi Rich, the fiberglass once set (making sure it is liberally coated with resin), will be waterproof, But I would just paint it or rust proof the whole area it as it would stop any further rust in the floor and maybe paint the front floor pan or any other area that needs it. The best place to buy the rust coat would be a bodywork shop or supplier as they would be the cheapest.
Cheers Pete

[OlliesLRover]

Hi Rich, the fiberglass once set (making sure it is liberally coated with resin), will be waterproof, But I would just paint it or rust proof the whole area it as it would stop any further rust in the floor and maybe paint the front floor pan or any other area that needs it. The best place to buy the rust coat would be a bodywork shop or supplier as they would be the cheapest.
Cheers Pete

Thanks Pete, that saved me heaps of $ and time, the kit only cost $30 and there was plenty to do the job plus it was much easier to do than I thought.

Regards
Rich

[flyreels]

Thanks Pete, that saved me heaps of $ and time, the kit only cost $30 and there was plenty to do the job plus it was much easier to do than I thought.

Regards
Rich

I am Glad it worked out well Rich, it looks good now mate.
Cheers Pete

[OlliesLRover]

If you have that much rust there I would be lifting the front carpet and checking the floor in the foot wells. This is another common rust spot as once the underlay is wet it takes a long time to dry out. Also check around the Alpine windows.


Well I decided to check under the front carpets and believe me you weren't wrong.

The passenger side was the worst, the underlay was soaked and the foam on the back of the underlay was as rusted as the floot well.

Judging by the amount of rust and slime on the underlay plus the condition of the foot well, it leads me to think it has accumulated over years, so it is difficult to judge how much water is leaking in at any one time.
Interestingly there was no pattern of water marks to follow to any of the major rust spots which were mainly on the floor it's self and in the corners and rounded bottom edges of the flywall, there was no trail or rust marks indicating that water had run down the flywall and into the foot wells.

Any way after many hours of drying, wire brushing and fibre glassing, then adding heaps of anti rust and kill rust the passenger side is done.

The drivers side was bad, but no where as bad as the passenger side, I finally got that side cleaned up as well.

Then after finding & checking the aircon nipples for blockages and finding none, it was time for the hose to come out, and yep you guessed it murphys law prevailed not a drop came through.

So I just went around looking for any sus areas that water may seep thru and went to work with the silicon.

Rather than go through the pain of having to pull the car to pieces to get the carpet out in the future (because there will be a future) what I did was slice the underlay from the front seats forward and followed the bottom contour of the consol to the start of the flywall, this way then I only have to take the carpet trim off, and fold the carpet back then I can take the underlay out in one piece, thus enabling me to check the floor on a regular basis after rain in approx 10min.

The other thing I did was get some thin ribbed rubber and place this on the floor first then put the underlay on top of that for 2 reasons:

1/ Because the foam on the bottom of the underlay is still rusted even after picking the worst of it out, so this will prevent this rust from working from the top down and causing havoc.

2/ Because the rubber is ribbed on the bottom I'm hoping any water that seeps in will just wet the floor and won't be in contact with the foam of the underlay, which I reckon is the bigger cause of rust than water just seeping in.

Regards
Rich

[jazzaD1]

my disco is rusty in the front passenger floor also, way less in the drivers though, I think I'll be buying a fibreglass kit also....

[MacMan]

Check the body mount on the firewall, passenger side. Disco's like cracking the firewall at that point - mine did, I welded it while my engine was out - and I'm certain it did nothing for waterproofing! The area cops some road spray. I have also had issues with leaking windscreen seals when installed by slobs.

[grumpster57]

hi,if you can see the rust along the bottom of the alp windows ,take the interior mould away and check the roof support,just replaced mine with fabricated one.also cut rut out of floor in back and front.i recomend using rust converter ,and opening any seams you can treat em paint em close em paint again ,also up high under dash where the dash sits on the body.replace underlay its cheap,with something that doesnt absorb water,just sayin

[SLOWBOAT]

I must admit I feel sorry for the next owners of your vehicles if this is how you patch them up.
I have a theory, do it once do it right.
When restoring mine I had all the rust cut out and repainted properly. It came up a treat and I also know that the structural integrity of the vehicle remains intact.
These vehicles will probably only be good for parts now as they will cost way too much to bring back to road worthy condition. JMHO!

[Utemad]

I must admit I feel sorry for the next owners of your vehicles if this is how you patch them up.
I have a theory, do it once do it right.
When restoring mine I had all the rust cut out and repainted properly. It came up a treat and I also know that the structural integrity of the vehicle remains intact.
These vehicles will probably only be good for parts now as they will cost way too much to bring back to road worthy condition. JMHO!

That pretty much sums up most Disco1s doesn't it?

Once you change the oil and fuel it up you have over capitalised.
I like mine but that is reality.

Easy come easy go.

[OlliesLRover]

I must admit I feel sorry for the next owners of your vehicles if this is how you patch them up.JMHO

Pity the bloke who sold it to me didn't have your high moral standards, but the next owner if there is one will be purchasing a vehicle in much better and safer condition because of the repairs I have done, than if I had done no repairs at all JMHO.

Regards
Rich

[Blknight.aus]

when you go in again.

get some of the rubber mat thats 2 rows of round rubber laid at 90 degrees to each other. cut that to shape and place it in in place of the underlay, it works best if you set it up so that the ribs run at 45 degrees to the vehicle.

when you dunk the car just lift the corners and then put small fans in and it'll dry out nicely.

Im currently gutting a disco1 let me know if theres any body bits that will be usefull to you and if they are salvageable I'll cut them out generously with the 5 inch fast spanner and then you can arrange transport at your liesure.

[OlliesLRover]

when you go in again.

get some of the rubber mat thats 2 rows of round rubber laid at 90 degrees to each other. cut that to shape and place it in in place of the underlay, it works best if you set it up so that the ribs run at 45 degrees to the vehicle.
when you dunk the car just lift the corners and then put small fans in and it'll dry out nicely.

Will do, thanks.


Im currently gutting a disco1 let me know if theres any body bits that will be usefull to you and if they are salvageable I'll cut them out generously with the 5 inch fast spanner and then you can arrange transport at your liesure.

Very generous of you thanks, I will keep it in mind.

Regards
Rich

[Blknight.aus]

be quickish Im hoping to have the body off and gone to the recyclers by the first saturday of december

[OlliesLRover]

be quickish Im hoping to have the body off and gone to the recyclers by the first saturday of december

I will have to pass then, but again thanks for the offer.

Regards
Rich

[OlliesLRover]

when you go in again.

get some of the rubber mat thats 2 rows of round rubber laid at 90 degrees to each other. cut that to shape and place it in in place of the underlay, it works best if you set it up so that the ribs run at 45 degrees to the vehicle.
when you dunk the car just lift the corners and then put small fans in and it'll dry out nicely.

Hi mate, called into supercheap and whilst I was there I found this Honeycomb mat (see pic) for $8 thought I would replace the underlay on one side with it and give it a try an see if it does the job.

Regards
Rich

[Blknight.aus]

that stuff will pool the water and not let it dry out...

https://www.aulro.com/afvb/images/imported/2012/11/222.jpg

This is the stuff you want (http://www.national-site-safety.com.au/vynalite-tube-welded-strip-anti-fatigue-mat-900-mm-x-10-mtr.html)

It does come in varying stiffness, with the round hollow tube stuff being the softest and the solid square stuff being the hardest

[OlliesLRover]

Thanks, I will keep an eye out for it.

Regards
Rich

[Anndra Ridh]

The water is probably coming in from the top of the rear door as it does not seal very well. Spray around with a hose and see where it is coming from.

Regards this, is there a way to improve on this? New factory rubber? Additional rubber? Membrane? :)

[460cixy]

This makes me think I better pull the carpet on my foot wells the rear load bay is fine