Boot floor replacement and rust fixing

well after this thread MOT-RUST-WILL PASS - pics on pages 1 and 3

Started to strip out the back and taken the boot floor out, checked the sills properly and well pics do the talking. .









is this the rear x member sill???





door sills drivers and passengers - had a good poke found one whole!








the drivers arch. . only one with rust on it at all. .



but been fixed before??
this is under the arch



passengers rear inner arch



found a guy who riveted in a new boot floor, so going to clean it all up replace the cross bits under the floor, repair around the arches, or replace and rivet in a new boot floor, patch the whole in the sills
and the arch - and finally replace x member at same time new body mounts.

also while im working on it im going to fit lower shock mounts and dislocation cones, inverted ones/ and lower front turrets and dislocation cones. . . along with new brake lines and wading kit

go for it!! yes it is the rear x-member in your pic, good luck with it all!

that dont look too bad mate..good luck with it.

Had to do mine a few weeks ago and it looked worse then yours, back door spring replaced so door would open back door couldnt open as cross member and mounts all rotted out, already done the boot floor but all ok now was worth a couple of days work to fix it rather then srapping it I would weld rather then rivit as much stronger but good luck and hope all goes well.

toyahwilcox said:

go for it!! yes it is the rear x-member in your pic, good luck with it all!

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mad mechanic said:

that dont look too bad mate..good luck with it.

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cheers

redrocky said:

Had to do mine a few weeks ago and it looked worse then yours, back door spring replaced so door would open back door couldnt open as cross member and mounts all rotted out, already done the boot floor but all ok now was worth a couple of days work to fix it rather then srapping it I would weld rather then rivit as much stronger but good luck and hope all goes well.

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how did you change the cross member i have no idea how its welded on or where lol!! its the only bit im stuck with!!

i was thinking rivits as they are cheaper lol an i can get my dads bro todo the patch work with his welder. . just gotta find the best way to weld the new cross member on!!

I made my cross member out of thicker steel so it was stronger and last longer but if you are buying a new one then undo the mounting bolts and cut out the the old one but dont get carried away, remember only cut out the amount you have to go back in for your new cross member and not bigger or you will have nothing to weld to.

I stripped mine out on yesterday and found that the floor was good just needed to scrub a bit of surface rust of, check with a poke of the screwdriver and overpaint. I'm not just writing this to be smug but I am pleased I have a rust free area. Now to the question: When I took up the soundproofing I found water lying on the boot floor, enough provide water for a small fish. I removed the sound proofing which seemed to hold water like a sponge, it's taken until today in the boiling heat to try out. Is this normal, the van has been standing for a while could it be condensation or do I have a leak or is this just normal?

sound deadening is notorious for holding water. It's why the floors rot out.

have ya got a rear sunroof ............ i bet thats been leaking without you knowing !!

oh yes! I thought it would be great for the kids! Would you recommend sealing it up? Or just checking and removing the sound proofing every month or so?

if ya dont use it much, seal the bugger up !!!

breakers said:

I stripped mine out on yesterday and found that the floor was good just needed to scrub a bit of surface rust of, check with a poke of the screwdriver and overpaint. I'm not just writing this to be smug but I am pleased I have a rust free area. Now to the question: When I took up the soundproofing I found water lying on the boot floor, enough provide water for a small fish. I removed the sound proofing which seemed to hold water like a sponge, it's taken until today in the boiling heat to try out. Is this normal, the van has been standing for a while could it be condensation or do I have a leak or is this just normal?

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when i took the sound proofing out it was sodden like a wet sponge lol

robint said:

if ya dont use it much, seal the bugger up !!!

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i love my rear sun roof, it lets mud and trees in!!!! gets the back seaters some entertainment!!

I had trouble with the tailgate door not sealing against the rubber and letting water leak in and flood the boot floor carpets, might be worth checking yours by running a hose at the top of the door, thats how i found my leak.

I shall do and then i'll report back. I'd like to keep the sunroof functional as the kids love playing with it but then maybe that's a good reason to seal it!

not necessarily the rear sunroof , ihad a leak off one of the alpine windows too...

Nice one!
that doesnt look too bad at all ref sills, etc...

just patch it all up...
I'll have to start welding some bits at some point before next March, luckly the boot floor has been replaced at some point, so it's all nice and new...but still have some patching to do in other areas...

[JP];800115 said:

Nice one!
that doesnt look too bad at all ref sills, etc...

just patch it all up...
I'll have to start welding some bits at some point before next March, luckly the boot floor has been replaced at some point, so it's all nice and new...but still have some patching to do in other areas...

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cheers got hold of mig welder so gonna do some practice at the weekend with it then get to work on the disco!!!

breakers said:

oh yes! I thought it would be great for the kids! Would you recommend sealing it up? Or just checking and removing the sound proofing every month or so?

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I stripped out the side trims around the windows + alpines and kept an eye open for leaks .
I resealed the alpines and then found a leakage coming from the outside gutter.
And only when I could not find anymore water ingress did I put the underlay back.
I still check underneath on a regular basis.

My floor was similar to yours found a leak from nearside alpine

Snow said:

cheers



how did you change the cross member i have no idea how its welded on or where lol!! its the only bit im stuck with!!

i was thinking rivits as they are cheaper lol an i can get my dads bro todo the patch work with his welder. . just gotta find the best way to weld the new cross member on!!

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I have similar floor rust issues and have been advised that rivets won't pass an MOT, has to be welded.