Rust Holes in the Floorboards

[cabanabob]

Getting caught up with the 'while your in there' projects that seem to be the norm when working on older cars. It all started with a new water pump and radiator.. Those new parts seemed to create a gushing heater core. After reading the forums (very helpful) I was able to begin the task of replacing the core. of course the carpet got ruined, so new carpet bought. Pull up the old carpet, and find the rust holes on the firewall. One is the size of a business card, the others smaller. Looking for repair suggestions that don't involve welding. Floors are solid, no other rust anywhere on car could be found. I've seen some posts where POR15 and fiberglass was used, but want to know if thats the best course of action or if there are other suggestions out there.

[basso]

Hi Cabanabob,
i wonder why You do not like to have it welded? A business card size hole in the firewall is not a smart repair.

There are two options that come to my mind: leave it as it is, drill it to a round shape, cut an hole wich the exact size in the isulation and the carpet and use it as an ventilation hole. The second is inserting an window with silicone and You are the onlyone beeing able to take a look at motor while driving...

Just kidding! There is nothing that can be done than welding a new sheet of metal in there. And if You do not like to weld ( or arent able to do this) perpare your Spider and let someone weld it ( its not that special and will cost less than using epoxy and fibreglass).

The part of the body is called firewall.... i hope no one ever needs it in this function, but when it comes to this, do you think that epoxy is a good firepreventer? I dont...

[DieselSpider]

Yes a firewall should be maintained with steel and not plastic resin.

[cabanabob]

Hey Basso--i do like the idea of seeing the ground below me. After looking through the many posts in the Restoration pages i will go find a welder who can come over and take care of the problem. appreciate the humor on the topic, as the project has spun beyond the 'out of control' phase. Next issue to tackle is the AC compressor that isnt needed anymore but has the alternator belted to it. That'll be the next 6 pack job...