Thread: Rust in D1 floors - any tricks?

Hey Mick,

I have the same issue, my floors aren't as bad but the side of my footwell has GONE!!!!! I treated light surface rust with a steel brush and then rust converter/eater but with heavier stuff I am going to buff it back with a grinder and then treat with red oxy paint in the hope it won't return! Side of well is having to be cut out and a panel welded on. God knows what they'll find when they remove the dash!?!?!?!?!?!?!?!?!?!?!? The A post appears to be rusted up there aswell but no marks on roof lining so no ideas where it's coming from. My drivers side has a small leak also but I think that may be from the door seals. Will look into it this weekend.

Good luck

I found a gap in the plastic strip above the windscreen on the passenger's side, so I'm assuming its been going in there. I'm going to fill it up with black silicon and see if that fixes it.

Nine times out of the water is coming from your air con. There are two drain hoses, one either side of the hump these tend to block up and the water over flows into the foot wells. Easy fix is to get under the car and push a long cable tie up the hose and let the water drain out. Also while under the car check the end of the drain hose, there are four flaps on each and these tend to stick together, I cut the tips off each one so that the water runs out.
Hope this helps.

Thanks for that, I'll have a look and try what you said, but I get water on the ground from the air con, plus I'm not actually using the air con at the moment and the underlay is still wet, which is why I was thinking it might be something else.

Originally Posted by DiscoMick

Thanks for that, I'll have a look and try what you said, but I get water on the ground from the air con, plus I'm not actually using the air con at the moment and the underlay is still wet, which is why I was thinking it might be something else.

cracks in your windscreen rubber or your alpine windows. the water leaks into the the body and runs down the inside of the roof line till it gets to your A pillars and then down and onto the floor, the underlay is just one big sponge.

cheers phil

In addition to treating the rust you also need to stop the water ingress. The water is probalby getting in through the ventilation/aircon system. The air inlet is in slightly different locations in the plennnum chamber that runs across the outside below the windscreen in pre and post 94 models. Remove the vent and check that none of the sealant in the plennum between panels and around the wiper motor mountings is cracked. On the pre 1994 models fit a baffle above the air inlet to stop water dripping in. ( I think post 93 models already have a baffle ?)

Regards

In addition to treating the rust you also need to stop the water ingress. The water is probably getting in through the ventilation/aircon system. The air inlet in the plennnum chamber that runs across the outside below the windscreen is in slightly different locations in pre and post 94 models. Remove the vent and check that none of the sealant in the plennum between panels and around the wiper motor mountings is cracked and that the drain holes at each end are clear. On the pre 1994 models fit a baffle above the air inlet to stop water dripping in. ( I think post 93 models already have a baffle ?)

Regards

Thanks. I've sealed up the plastic strip above the windscreen and plan further investigaitons at the weekend, so I'll have a look at the vents under the wipers.