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Old 01-27-2011, 03:50 PM   #1
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Floor Rust Repair

Looking for a no-weld floor rust repair solution. Currently I don't know how to weld and don't know anyone that can do it for me. I would rather not pay someone to do it either. Has anyone repaired the floor panels without welding? Whats some steps I should take? And what do I need?

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Old 01-27-2011, 04:14 PM   #2
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cut out bad metal
clean predrill and rivit in new sheet metal
over lap and seal with waterproof tar

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Old 01-27-2011, 06:10 PM   #3
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NO TAR! Silicone if any thing.
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Old 01-27-2011, 06:46 PM   #4
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Was told before about using black jack... supposedly it dries in minutes and has no smell. figured it would add to the seal if i put it between the floor and new panel when riveting. or maybe some jb weld? then bed line of course
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Old 01-27-2011, 07:22 PM   #5
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I'm about to do the same thing on the van I picked up to haul my dirtbike. I bought that POR 15 stuff to treat it and will probably just rivit or JB weld a plate over the bad spot and then seal it.
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Old 01-27-2011, 08:07 PM   #6
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I had someone tell me up use fiberglass and pot 15. You would clean up the loose rust with wire wheel and/or die grinder. Then por 15 it to stop any future rust. Then lay a 3 strips of fiberglass on it. Followed by another coat of por 15. Between the 2 products you would end up with a solid floor.
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Old 01-27-2011, 08:22 PM   #7
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As said by markharmon,

Fist, buy Marine Clean, Metal Ready, fiberglass matte, and POR-15. Take a wire brush and get as much loose rust up off the floor as you can. Vacuum it out good. (Now take your fiberglass matte and lay it on the floor pan and cut it so it fits in there nicely. Then cut slits in the matte where those grooves in the floor are. This will allow the matte to fill into those grooves a lot easier later on. After it's fit how you want it, take it out so you can do the prep work). Then saturate the rusted areas you wish to cover with the Marine Clean and let it soak for 15 minutes. This will get rid of all greases and oils and dirt. Rinse it out with a hose and let it dry completely. Then saturate the area with Metal Ready and let it soak for 15 minutes. This will pit the metal and prep it for the POR. Again, rinse it out with a hose and let it COMPLETELY dry. Next, apply the POR-15 to the rusted areas that you prepped. Don't be shy with it either. Really slap it on there. Now, lay down your fitted fiberglass matte and just dab it onto the POR. Lastly, using a brush, apply another layer of POR ontop of the matte. Use a dabbing technique to get the POR into the fabric. Let it all dry, then bedline *I also got under the Jeep and did the same thing on the underside of the floor pan just for extra security. It didn't need it but I did it anyways*

My 92 YJ so far

Here's my thread. Check it out. This is how I solved my floor pans.
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Old 01-30-2011, 08:33 PM   #8
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Warning!!!!! Make sure you completely cover your skin before using por15. If it drys on you it will have to wear off.
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Old 01-30-2011, 11:07 PM   #9
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Quote:
Originally Posted by YJman View Post
As said by markharmon,

Fist, buy Marine Clean, Metal Ready, fiberglass matte, and POR-15. Take a wire brush and get as much loose rust up off the floor as you can. Vacuum it out good. (Now take your fiberglass matte and lay it on the floor pan and cut it so it fits in there nicely. Then cut slits in the matte where those grooves in the floor are. This will allow the matte to fill into those grooves a lot easier later on. After it's fit how you want it, take it out so you can do the prep work). Then saturate the rusted areas you wish to cover with the Marine Clean and let it soak for 15 minutes. This will get rid of all greases and oils and dirt. Rinse it out with a hose and let it dry completely. Then saturate the area with Metal Ready and let it soak for 15 minutes. This will pit the metal and prep it for the POR. Again, rinse it out with a hose and let it COMPLETELY dry. Next, apply the POR-15 to the rusted areas that you prepped. Don't be shy with it either. Really slap it on there. Now, lay down your fitted fiberglass matte and just dab it onto the POR. Lastly, using a brush, apply another layer of POR ontop of the matte. Use a dabbing technique to get the POR into the fabric. Let it all dry, then bedline *I also got under the Jeep and did the same thing on the underside of the floor pan just for extra security. It didn't need it but I did it anyways*

My 92 YJ so far

Here's my thread. Check it out. This is how I solved my floor pans.
Can you give a bit more detail on the fiber glass part? I bought the POR15 starter kit with the Marine Clean, Metal Ready, and POR15 pain, but I'm not sure how to use the fiberglass with it . . . I've never used fiber glass before . . . is there a special kind to buy, do you use multiple pieces/layers to make it thicker, how long do you wait between POR 15, placing the matte and the second coat? I was planning on putting down some sheet metal but this sounds like it might work better.

Thanks!
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Old 01-31-2011, 10:43 AM   #10
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It was my first time using fiber glass too. I bought a coarse matte. I bought mine at walmart in the automotive dept., it works fine. After you apply your first thick coat of POR, you can put the fiberglass on it right away. And sort of press the matte onto the POR. Then take your brush with POR on it and dab in onto the fiberglass matte. Add some pressure so the bristles penetrate the cloth. You want the matte soaked in POR. You can add more layers following the same steps as you please.

Here's what the fiberglass matte looked like (there;s 2 sheets in this picture):
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Old 01-31-2011, 01:14 PM   #11
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Thanks YJman . . . How many layers of fiberglass matte did you use?
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Old 02-01-2011, 08:07 AM   #12
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No problem. I used one on top and a small patch where my big hole was on the bottom. If you don't feel like doing the one on the bottom, I'd put at least 2 on top. Then just POR the bottom when you get a chance.
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Old 02-01-2011, 08:54 AM   #13
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Quote:
Originally Posted by YJman
As said by markharmon,

Fist, buy Marine Clean, Metal Ready, fiberglass matte, and POR-15. Take a wire brush and get as much loose rust up off the floor as you can. Vacuum it out good. (Now take your fiberglass matte and lay it on the floor pan and cut it so it fits in there nicely. Then cut slits in the matte where those grooves in the floor are. This will allow the matte to fill into those grooves a lot easier later on. After it's fit how you want it, take it out so you can do the prep work). Then saturate the rusted areas you wish to cover with the Marine Clean and let it soak for 15 minutes. This will get rid of all greases and oils and dirt. Rinse it out with a hose and let it dry completely. Then saturate the area with Metal Ready and let it soak for 15 minutes. This will pit the metal and prep it for the POR. Again, rinse it out with a hose and let it COMPLETELY dry. Next, apply the POR-15 to the rusted areas that you prepped. Don't be shy with it either. Really slap it on there. Now, lay down your fitted fiberglass matte and just dab it onto the POR. Lastly, using a brush, apply another layer of POR ontop of the matte. Use a dabbing technique to get the POR into the fabric. Let it all dry, then bedline *I also got under the Jeep and did the same thing on the underside of the floor pan just for extra security. It didn't need it but I did it anyways*

My 92 YJ so far

Here's my thread. Check it out. This is how I solved my floor pans.
Hey where in ct r u from I saw ur thread and noticed the ct plates
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Old 02-01-2011, 09:20 AM   #14
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Branford CT lol. So is my friend on here who owns a TJ
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Old 02-01-2011, 09:58 AM   #15
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Ohh nice I'm in the Fairfield Bpt area!
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Old 02-01-2011, 10:21 AM   #16
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Oh sweet! Crappy weather here today.. Supposed to be snowing but its raining.
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Old 02-01-2011, 11:14 AM   #17
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Haha yep all sleet i had to drive my sis to work in the morning her AWD BMW was terrible haha
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Old 02-01-2011, 07:36 PM   #18
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Fiberglass is a lot like bondo. You have to mix 2 part resin. In my opinion you would use the metal clean and etch supplies. Then paint on a good layer of por 15. Let the por 15 completely dry per directions. Then mix up resin. Paint on a layer of resin then lay down a layer of fiberglass. Then add more resin to soak the fiberglass. Make sure fiberglass is pressed down against metal and no air bubbles. Let dry. Then apply another layer in opposite direction same as before. Layer of resin, layer of glass then coat with more resin. 2-3 layers of glass should be plenty. Lastly more por 15.

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