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  #1  
Old October 2nd, 2011, 03:40 PM
flananuts
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Matthew
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Bulkhead rust advice - PICS INCLUDED

In preparation for putting in new floor tins in the footwell, I removed the majority of the trim on the bulkhead and found rust all along a common line. I knew my ST doors leaked into the truck as well as water leaking down the bulkhead somewhere. I'm not looking for pristine when done, however I would like to remediate what I can and make the "Rusty Onion" a little less rusty and a little less leaky. Here are some photos I took of the rust on the bulkhead and the footwells.

https://picasaweb.google.com/1182516...71717125886290
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  #2  
Old October 2nd, 2011, 07:48 PM
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Phillip
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wire brush Ospho rustoleum and waxoyl. A LWB I look after had the rear load space rotted out, I was suprised at how well the Ospho impacted the rust. Its too bad, nearly every defender I see has wet carpet or water under the matts, at least you were able to catch it before it got worse. Range Rover Classics are the absolute worst, that foam bullshit is the best sponge ever.
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  #3  
Old October 2nd, 2011, 08:07 PM
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William Skidmore
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Quote:
Originally Posted by rover4x4 View Post
wire brush Ospho rustoleum and waxoyl. A LWB I look after had the rear load space rotted out, I was suprised at how well the Ospho impacted the rust. Its too bad, nearly every defender I see has wet carpet or water under the matts, at least you were able to catch it before it got worse. Range Rover Classics are the absolute worst, that foam bullshit is the best sponge ever.
What he said.
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  #4  
Old October 2nd, 2011, 10:28 PM
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Bill Adams
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I prefer the POR -15 treatment, but you must follow the process they provide to the letter.
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  #5  
Old October 3rd, 2011, 06:21 AM
flananuts
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Matthew
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Thanks for the tips. I'm fairly certain I'm getting water through the vents even when closed so a new set of seals are in order. What I am not certain of is that the major leaky area? Does the pics look more like external surface rust and rusting through?
I plan to do a little water test to spot all the areas where the water is coming through and Solon share my findings.
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  #6  
Old October 3rd, 2011, 02:30 PM
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If you are going to have this truck for more than 3 years and have the money go new bulkhead.
Unless you cut ALL the rust out like a cancer it WILL come back.
Ive used POR, rust converter etc.. and none will last
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  #7  
Old October 3rd, 2011, 03:12 PM
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Ive been experimenting with Easton's rust encapsulator and extreme chassi paint, the reviews seem good.
Por15 even with decent prep flakes and cracks after a while and water gets beneath it- good for a year or two but thats all. As mentioned, wire brush, then sand, wash, degrease/prep, Ospho, easton encapsulator, then paint, then waxoil.

The encapsulator lays down and fills very good, is brilliant with sliders, bumpers etc with extreme chassi paint on top, as far as the finish goes as good as a powder coat look/finish. How it will do in the long run will see after this winter.
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  #8  
Old October 3rd, 2011, 05:11 PM
flananuts
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Matthew
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I'll keep pics of what transpires as I peel back more layers of the "Rusty Onion". My pops is spending the month of November in my town due to baby #3 aka "Baby Brother" arriving. He's wicked savvy with new metal and a Mig Welder. At least I'll save some money on the labor when the new footwells go in.

For some muscle car porn, check out his photo gallery on his 67 chevelle SS 396. True Garage job
https://www.facebook.com/media/set/?...7019260&type=1
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  #9  
Old October 13th, 2011, 06:29 PM
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Matthew
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Update- I pulled up the floor pans and the rust in the footwell is limited to the lower portion. I think I'll be able to cut out and plate in new steel and weld in. The drivers side is worse than the passenger side so I'm cautiously optimistic that I can stem this. After further inspection along the bulkhead it's looking like, outside of the vents leaking(which I knew), it's still pretty tight. The bits o rust along the top edge of the footwell so far seem to be surface so I think there's hope here.

Question, what gauge/thickness should I get to replace the rusted portions? I can't seem to find any real good detail on this.
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  #10  
Old October 13th, 2011, 08:23 PM
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William Skidmore
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You might want to waxoyl your truck or at the least the bulkhead too.
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  #11  
Old October 13th, 2011, 09:51 PM
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Dana Hammersley
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I think you better just sell it to me cheap and be rid of it. You probably don't want to piss with all the work anyhow. LOL
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  #12  
Old October 14th, 2011, 04:37 PM
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Matthew
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trust me, the price I paid for it, what you would consider cheap would likely be a nice profit. But then I wouldn't have my "rusty onion" and then I'd be very sad unless it was replaced with a 110 convertible on a galv chassis with a 5L rover 360HP motor. One can dream
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