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I'm hardly an expert on this...
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Posted by Snowmobile [Email] (#686) [Profile/Gallery] (more from Snowmobile) on Sat, 30 Apr 2016 18:25:06 Share Post by Email
In Reply to: Footwell rust repair, Glen in Montreal, Sat, 30 Apr 2016 14:14:10
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but I have BTDT... 1989 winter beater sedan.

The floors rust from the inside out. It is easy for moisture to get trapped in the sponge based acoustic damping layer and not ever dry out. I tossed ours. They were soaked. Floor was a mess. I think it is from people tracking moisture in rather than leaks. Anyway, I stripped the interior, scraped and wirebrushed like mad. POR15. Heaps of it. Actually a great trick from them is to paint the stuff with POR15, soak fibreglass in POR15 and paint it all in place. I actually left the middle (there were significant holes) uncoated, so then subsequent layers using fibreglass resin, I could patch cloth on both sides and adhere through the layers with resin inside to outside the car.

Messy, big job. Others have welded. Photos are in my gallery, but here is a before/after:





It's been about 2 winters now and it seems to be holding up well. This car is thrashed in salt slush snow all winter.

good luck!

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