3 ms·

That's not even really severe rust - most of it is just surface, easy to treat it with naval jelly/rust neutralizer.

• kube-system 5y ago
  The second photo shows two large holes in the driver footwell and one in the passenger side. The last 4 photos show where it was cut out and patched. It's not difficult to patch with some sheet metal and a welder, but it's labor intensive.
  • jacquesm 5y ago
    It can get difficult in a hurry if the rusted out spots are near where wiring is sandwiched between the various metal parts. I've done my share of repairs like these and if you only end up doing what you think you'll be doing when you start the job then consider yourself lucky.
    • kube-system 5y ago
      I've done one myself. In my experience, the worst part is removing sound deadening and factory undercoat.
      • jacquesm 5y ago
        Yes that can be quite tricky. For sound deadening: the method I use: first try a couple of different ways on a small test patch, then do the whole thing. Methods to try: chisel, applying a bit of heat, cold spray and then hitting it with a hammer (surprisingly effective!), large diameter rotating steel brush (not very good for detail work due to the large diameter but it eats through that stuff in a hurry), pushing 'up' from below to deform the floorpan a bit to see if the stuff delaminates (sometimes you get lucky). Pick the one that works best for the initial removal, then do the remainder with the next slower method until it's done. Tedious. Factory undercoat: rotating steel brushes are the only effective way afaik and it takes forever unless you have access to a large size sand blaster.