Rusted front floor panels on tdi 2 door

[landyadrian]

Hi everyone wondering what your thoughts are on spending 3200 dollars on repairing rusted floor panels and door seal panels. These vehicles seem hard to get.

[DAMINK]

I had some rust in my D1 floor.
Got some metal from the local steel place.
Beer from the local bottleshop and went at it.

Easy enough to do if your able to weld man. 3k is way too much! Unless your whole floor is rusted!

[grey_ghost]

Depending on how bad the rust is / how structural it is, I have used a steel sheet cut over size, silkaflex and pop rivets... [emoji1303]

[DAMINK]

Depending on how bad the rust is / how structural it is, I have used a steel sheet cut over size, silkaflex and pop rivets... [emoji1303]

That would work just as well and i have heard of that method several times. Welding these floor panels is not easy for a novice welder or first time welder.

Yea its hard to tell until you strip it all down and wirebrush basically the whole floor. I thought i had some pin hole rust spots until i took the whole interior out.
Turned out both foot wells were rusted at the curve bit where your feet typically sit. I cut out about a 300mm square piece on either side and welded a new one back in.

Painted the whole floor white and put the carpet etc back in.

Reasoning being that if rust starts again i may be able to see the red stain easily on the white surface identifying any future rust quickly.

[landyadrian]

That would work just as well and i have heard of that method several times. Welding these floor panels is not easy for a novice welder or first time welder.

Yea its hard to tell until you strip it all down and wirebrush basically the whole floor. I thought i had some pin hole rust spots until i took the whole interior out.
Turned out both foot wells were rusted at the curve bit where your feet typically sit. I cut out about a 300mm square piece on either side and welded a new one back in.

Painted the whole floor white and put the carpet etc back in.

Reasoning being that if rust starts again i may be able to see the red stain easily on the white surface identifying any future rust quickly.

Ye this is both front floors past the bend by the brake pedal around the seal panel were the seal clips on .

If I’d known it had been leaking would have been on to it. But not much rain in Alice and didn’t notice.

[jboot51]

Land Rover Defender RHS Footwell DA6101 | eBay (https://rover.ebay.com/rover/0/0/0'mpre=https%3A%2F%2Fwww.ebay.com.au%2Fp%2F1102082 7186%3Fiid%3D173380892028)

These would make for a nice finish.

[DAMINK]

Ye this is both front floors past the bend by the brake pedal around the seal panel were the seal clips on .

If I’d known it had been leaking would have been on to it. But not much rain in Alice and didn’t notice.

I suspected mine was caused by mud buildup and lack of cleaning.

You any good with a welder? The way grey_ghost suggested is a good idea. Its not "pretty" like a welded one but it works just as well. And does not involve special tools.
My way of thinking is dont be shy. Rip the entire interior out. Leave the dash and cover the hell out of it.
Get a look at the work ahead. Plus using power tools inside the cabin is going to make sparks so just get it all out.
Cut out all the cancer yourself with a grinder and a 1mm disk. Make sure your cuts go well past the cancer! Try keep the cuts as square as possible to make replacement easier.
Get some sheet metal. 1mm or whatever it is. Bend to shape and do either to repair.

Sounds hard but its actually not a bad job. I can think of 10 worse ones to do on a disco.

[pop058]

Land Rover Defender RHS Footwell DA6101 | eBay (https://rover.ebay.com/rover/0/0/0'mpre=https%3A%2F%2Fwww.ebay.com.au%2Fp%2F1102082 7186%3Fiid%3D173380892028)

These would make for a nice finish.

Disco 1 not Defer. [biggrin]

[jboot51]

Disco 1 not Defer. [biggrin]

Ahhh, I my bad.
I thought 2 door defender, and we'll worth trying to save.

Taking a welder to a disco would take a lot of prep work with removing all the sound deadening etc.