On Fri, 6 Jun 2003, ian Butler wrote:

> I managed to clean up the sandpapery, rusty undersides of the mats, and I'm
> going to thoroughly clean up the entire floor tomorrow.  (It's a bit smelly
> after sitting in stagnant antifreeze for untold years.)  I'm not entirely
> sure how to fix the holes and other rust damage, though.  It looks like I'm
> in for many long evenings with a Dremel and POR-15, and some sort of body
> filler.  Any recommendations?

I wouldn't use body filler.  It's strictly for cosmetic smoothing
purposes, probably and won't hold up here.  You'll just end up with a
bigger hole later.

Since this is a floor, you have the advantage of not having to care what
the repair looks like.  The *best* repair would be to cut out the
rusted-through areas and weld in new metal.  Failing that, cut out the
rusted-through areas and install a patch with sheet metal screws.  Use
liberal amounts of POR-15 to discourage rust in the overlapping areas,
which have the potential to trap water.  Undercoat the repair when you're
done.  The ideal patch would be a piece cut from a donor van (since the
contours would match) but any piece of sheet steel you can get to fit will
do.

If you're careful the repair will be as strong as the original floor.

David Brodbeck, N8SRE
'82 Diesel Westfalia
'94 Honda Civic Si