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Discussion Starter · #1 ·
I have an 87 240 wagon with rusty floor pans. I want to deep it alive for 3 more years while my daughter is in college. Any quick and dirty ideas on how to patch the rust? It is rusted all the way through in about 5 different spots- one of them pretty big
 

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Re: Rusty floor pans (wingnut)

<br> Quick and dirty will give you about 1 year of service.<p> Cut out the old, weld in the new, Seal, prime, rust-proof.<p> Use rubber floor mats in the winter, and rotate them out so the floor stays dry.<p> DGDrls <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/smile.gif" BORDER="0">
 

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Re: Rusty floor pans (DGDrls)

Welcome to Swedespeed, Jeffrey.<p>If you plan to eventually crush the 240 then just cut some scrap thin plywood to fit on top of the rusty footwells and cover with carpet remnants.<p>George Dill<p>
 

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Re: Rusty floor pans (wingnut)

<br>cheops method<p>threaded rod filed to fit 1/2 milwaukee. red locktite with complete grade 8 hardware and center 4-5" circular wire brush. place fuel line hose on rod/grease to hold brush onto pan. BRUSH! use Tide paste - wear mask.<br>paint with rusto system. LET DRY!<br>eat breakfast. take apart cereal box. reassemble.<br>go to furniture store and beg cardboard for floor pan template.<br>cut and fit template to pan - accurately! - use new razors - level straight edge<br>trace template to 14 Ga? (i forgot-maybe 16) use razor<br>cut with correct snips (buy) straight cut right?<br>bend using 2x4 and deep reach clamps<br>the sides go up under door sills and pop rivit there - with the tar/linseed coating and onto the trans tunnel - and up to the pedals. <br>paint.<br>using trowel grade Century (or best grade available) roofing tar and best grade linseed oil<br>coat pan with linseed - dry<br>mix tar with some linseed if possible<br>spread hot roofing tar thinly - 1/8" - on pan - is best to do this in sun on a very hot day for uniform spreadability<br>using 2x4 and or only 11 pound enginners hammer (HD)<br>tap 14/16 Ga down onto vehicle pan - center out like with bodywork<br>drill and pop rivit (means the pan's bottom needs brushing also)<br>pop rivit gun will clog with tar so have two on hand.<br>buy boxes of the best quality poprivit and paint over when done as rivits corrode<br>rivit every 1" - like the welds on a 544!<br>
 

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Re: Rusty floor pans (datakoll)

more cheops -<p>1/8" is a bit thick but the idea is to keep a tar film under the new pan<p>the rusto is rusty metal rusto. one coat thinned to settle in, one thick. dry to the point where coating with linseed will not dissolve the rusto<p>same for the linseed - tacky is ok<p>a tool - hardwood block cut from skid less than the area from one rivit hole to another. drill hole slightly larger than rivit hole. use stiff wire -antenna? -<p>locate hole, tap block down forcing pan onto tar/linseed/rusto<p>work from center out. use wedge hardwood tap to spread pan out over tar then block hole tap.<p>eliminate air pockets. dimpled pan effectively strengthens the piece.<br>
 

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Discussion Starter · #7 ·
Re: Rusty floor pans (datakoll)

That was my original idea and so far it is working OK. Thanks for the validating of my idea of the sheet metal
 
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