Rust in footwell of 130

[clankilpatrick]

Good Afternoon everyone,
I posted this query (Rust problem)[URL="http://www.aulro.com/afvb/90-110-130-defender-county/65657-rust-problem.html"] onto the defender chat area a couple of weeks ago and have had a number of people look but offer no advice. It seems that I must be the only bloke with the only defender that has rust in it. Thought I would try a more general approach and see if anyone has done this sort of repair before. So here goes again.
Good morning All,
I hope someone may have some ideas on best how to deal with the hole in the footwell under the accelerator pedal of my 130. The piccy attached will probably explain it better then I can. The black stuff is rust converter from a previous patch and paint job but I couldn't help myself and started digging around with a screwdriver didn't I. Is it possible to get replacement footwell panels and if so is it a difficult job to put them in or is the best approach just to carefully cut the rust out and weld in some replacement metal?. Any advice or thoughts would be greatly appreciated. Many Thanks, Dave

[langy]

I haven't done this so others who have may dissent.

To the best of my knowledge, the firewall area around where the right foot goes has not changed in dimension since the series III. You should be able to find a suitable donor, cut out a slightly oversized patch and MIG it in. I'm not aware of replacement sections in Australia for the firewall in the footwell area ( Although I suppose you could find an aftermarket supplier in the UK).

[mike 90 RR]

cut out a slightly oversized patch and MIG it in.

Yep x2 ... It's flat metal ... easy :)

[Blknight.aus]

if your metal bending skills arent up to it and you want a flash job you can get the sections of the foot well online from several places in the UK and then weld them in.

or go find a rolled over wrecked one (even a series will do as the angles are the same) cut the chunk out of that that you want, dress it and weld that in.

[malsgoing130]

My 96 130 has minor rust in both foot wells, I've sprayed rust converter and primer on for the mean time but it seems a proper job will have to be done one of these days, I've also got it creeping up the sides of the foot well just on the bend to the door opening, that worries me more, looks like a pain to weld in and paint the back side of it. Some one wrote some where in here to leave it until you can see the road then repair it, that might be the best advice:D;)
Malcolm

[clankilpatrick]

Good evening Gentleman,
many thanks for your advice. I have been having a closer look and the "back" wall of the floor pan looks to have some "ribs" pressed into it for structural strengthening, but I reckon your ideas of cutting out the cancer and just MIGing in a new sheet will probably be the go. The hole in the floor is big enough now that I can just about poke the big toe through and rest it on the cross member. Not good for dusty conditions.
cheers
Dave

[DeeJay]

Four Wheel Drives here in sunny Melb have them ( for a series vehicle at about $55.00 each side. Looks like a cut out & weld in job. P/NO P10D is right hand
Phone 03 9890 0599. - They could tell you if its the same for a deefer- I reckon close enough.

[clankilpatrick]

Thanks for the input. Am cutting out the first sheet and will fix up the rust in the second sheet by cutting it out and migging in some new stuff and then putting a plate back in over the top that can be removed easily for regular rust inspections
cheers
Dave