Rusty floor board

seanj · Post by **seanj** » 01 May 2016, 18:59

So, as I wait for better weather to show up so that I can put my carpetting back together post heater control valve replacement....

I found a nice hole in the front passenger side floor pan - its about 6 inches wide (sideways in the car) by 2 inches long (across length of car). Disappointing....but rest of the car is solid with very little rust.
The surrounding metal is strong and looks fine. I called a local body shop and they quotes me $1000 to do the job - seems a little excessive for me.

Here's what I am thinking - cleaning up the metal, hitting it with a wire brush. Using the POR-15 cleaner degreaser, followed by POR-15 prep & ready.
I plan to buy 1/4" thick 6" x 6" Aluminum T6061 plate and coating with the chassis coating black paint from POR-15 - followed by liberal usage of JB weld marine epoxy steel to bond the aluminum plate onto the car.

I intend to "seal" the joint between floor pan and the aluminum plate both inside and outside the car.

FYI - I will be attaching this aluminum plate from inside the car. I considered galvanic corrosion due to dissimilar metals - but this car never sees snow anymore - so I doubt it if there will be a conducive moist environment with an electrolyte (road salt) that will facilitate the galvanic corrosion.

My long term plan is cut the entire floor pan in a few years and weld in a new one.

Thoughts, comments, advice??

lummert · Post by **lummert** » 01 May 2016, 19:40

Steel sheet metal patch. Remove rusty metal. Attach patch using body panel adhesive.

seanj · Post by **seanj** » 01 May 2016, 20:04

Does it have to be steel only? Aluminum composite won't work?

Apart from the galvanic corrosion creep due to dissimilar Metals (which like I said in my original post - I don't think should happen since I won't be driving the car in winter - it sits in inside non temperature controlled storage).

From a materials standpoint - the t6061 Al sheet should be better for corrosion and longevity versus anodized steel sheet and also be stronger.

lummert · Post by **lummert** » 01 May 2016, 21:22

Aluminum may work okay, just don't need 1/4 inch thick aluminum plate when aluminum sheet metal is strong enough.

seanj · Post by **seanj** » 02 May 2016, 07:18

Thanks. You are right - I will go with 1/8" Al T6061 instead.

93Regina · Post by **93Regina** » 02 May 2016, 23:23

Google: Volvo 240 Floor Pans

Video 1800 Floorpan Install

seanj · Post by **seanj** » 04 May 2016, 19:40

Appreciate it. That's what I have been using - googling 240 floor pans.
The video is more involved than what I can at this point - that however, is my goal few years down the line.

Should have my car back up sometime next week.