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  #1  
Old June 9th, 2015, 07:39 PM
alecbeard
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Alec Beard
1972 Series III
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firewall rust

You know the problem: where steel meets aluminum. I have a bit of rust in the corners working from the inside out on a 1972 series. I'm wondering what people do to stop it.

Should it down a bit and put on some POR 15 or other rust-proof paint? I'm just afraid that unless I get rid of all the rust, it will keep spreading. And if I get rid of all the rust I will have holes in my floor. If that's the best option, how would you patch the holes?

Thanks in advance. I just bought a new rover and am a little worried about keeping it nice.
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  #2  
Old June 9th, 2015, 08:30 PM
Ignotus
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gene
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Depends on how bad it is. There are complete replacement footwells, cut the old one out and weld in a new one. No aluminum in the bulkhead.
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  #3  
Old June 9th, 2015, 08:58 PM
alecbeard
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Alec Beard
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Quote:
Originally Posted by Ignotus View Post
Depends on how bad it is. There are complete replacement footwells, cut the old one out and weld in a new one. No aluminum in the bulkhead.
It's not too bad I don't think. If I cut out all the rust, I would have a 6"x2" hole maybe. Problem is, I'm not a great welder, and welding two different metals is tough, right? Any other options?
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  #4  
Old June 10th, 2015, 09:29 AM
slorocco
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Dan Prasada-Rao
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The bulkhead is all steel, welding should be no problem.
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  #5  
Old June 10th, 2015, 11:30 AM
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Will
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Post a picture.

If all the rust you have only creates a 6" x 2" hole, consider yourself lucky.

That is probably a $50-$100 repair if you have a shop do it.
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Old June 10th, 2015, 05:30 PM
alecbeard
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Alec Beard
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Quote:
Originally Posted by slorocco View Post
The bulkhead is all steel, welding should be no problem.
But the body is aluminum. Where they meet is where the rust is

------ Follow up post added June 10th, 2015 03:31 PM ------

Quote:
Originally Posted by Contractor View Post
Post a picture.

If all the rust you have only creates a 6" x 2" hole, consider yourself lucky.

That is probably a $50-$100 repair if you have a shop do it.
Thanks. I'll try to take a pic. Yeah I'm probably being overly protective, but I just don't want to have to replace the entire bulkhead one day. That sounds like a real job
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  #7  
Old June 10th, 2015, 07:11 PM
Lemonhead
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TB
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Would have to see pic to get better idea but I've had a lot of success patching holes with Por 15 soaked fiberglass. Dries rock hard and can hardly knock down the high spots with a grinder.

Key is you typically have to get to both sides to do it "right".

Yes - "right" would be welding or replacing but depending on where the issue is - this is a quick durable (and so far permanent) fix for my needs.
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  #8  
Old June 10th, 2015, 07:49 PM
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rijosho
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Joshua
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Pictures?
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I am talking purely from an aesthetics standpoint.
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