General rusty floor pan, pictures attahced

[pondy]

i no there was rust spots coming through on my floor pan and have planned to wire brush it down and waxoyl it next saturday. put it up on the ramp today just to have a better look on how bad it is, its worse than i expected, has one hole and some other areas were the rusts needs cutting out and plates welded in.

in the floor pan there arte a few half moon cuts out, if you bend them back there is a rubber bung that when removed goes all the way to the carpet inside, every one of these has bad rust, see pic

at the rear of the car only there are to parts that look like jacking points but are no were near strong enough and just crush in, these look to be held on with a few spot welds and its rusted bad between to two metals. on side is rusted, the other is worse and has a hole.

the half moon cut outs with the rubber grommet i plan to cut out and weld a plate in, these seem totally pointless being there and just cause me trouble.

the jacking points at the rear im not sure on, i never use them, if im working at home i use the sill, the front subframe or the rear axle depending on what im doing, or take it to work on a ramp.
as its rusting all the way around the area i doubt you will get rid of the rust without cutting it out and replacing the part which i have been unable to find. can i cut there part out and weld a plate in its place? its not being used and is not a structual part as its held on with spot welds

sam

 

[eamonnf]

Ouch! What year is your car? I have 2001 with some areas that of concern but on roof not floor...

 

[pondy]

2005 with 56k

stripped back the carpet and sound proofing. 11 holes in total to fix.

8 due to fiat adding half moon cut outs in the floor pan, you can see the water under the sound proofing.

 

[Focus Owner]

you might be still under fiats perforation warranty.
check your docs

 

[pondy]

its never been to the dealer since i have owned it so its never had its yearly body and paint check

 

[Ziggy122]

Some of that is surface rust

get a Wire Drill Attachement - and spend a good day cleaning the worst spots up
Wack a Good couple of layers of Waxoyl on it to stop it getting worse (it suffocates the rust = wont get worse)

If the rust is More then just surface - ie it comes off in huge flakes and you've got a hole

Get the Rust area Cut out (after battery and ECU have been unplugged/Removed) and get them welded up with quality Materials - making sure you give the interior a Spray up with primer and a colour to seal the interior - and the Underside - give the whole area a really good few coats of waxoyl - its very important that you do

Ziggy

 

[wilko1992]

Thats the same places as my mk1 1996 punto except i onley had 3 but all rust cut out now and new metal welded in seald inside and underseald the whole of the outside.

 

[DaveMcT]

Welding is the only option. Ideally find someone who uses gas welding for a properly good job. Any box sections will need to be sealed inside as the welding burns off the internal protection. Without that the car will drop to bits even faster and you wont know until its too late.

Also find out why the floor was wet. Dont assume it was the rust holes letting in water.

 

[pondy]

doing all the welding myself, 2 holes done now

the water has not come in because of the rust, its come in because of the open drain holes in the floor pan, got trapped under the sound proofing on the floor and corroded around the drain holes and only drain holes.

the only other part the chassis is rusted on is the rear jacking points, held on with 4 spot welds and no flange sealer, to disimular metals is asking for rust

 

[corky]

my sills and floor were like that it took a full day to weld and it cost me £120 and mine were really bad!!

 

[tinytim]

I think the rusted area with the bolt/nut showing might be the seat belt attachment point; my punto is rusted there also.
Have you tried wire brushing where the sills join the floor pan? I removed the seam sealant and found horric rust, still unsure what to do about it.
Did you have to remove the seats to do the welding?
What type of elding did you use

 

[tinytim]

sorry welding not elding...