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Old 05-17-2018, 12:13 PM   #1
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Replacing Metal Floor?

I spent the weekend tearing up the wood floor of my bus and got it down to the metal below (which was a pain in the tush as most of the screws holding the plywood down were rusted and I had to tear up the wood around the screws). I then used a grinder to remove most of the rusty screws (although I couldn't get many of them out- I just ended up grinding them down to be level with the floor).

I am now left with a bunch of screw holes, a few holes of larger size that I assume were from pre-existing hoses, and some rather large rust holes (pics below). I was originally planning on patching these holes with epoxy or welding patches but I am wondering if anyone has messed around with just replacing the metal floor altogether? Or should I just grind the heck out of the rusty spots and patch?

It seems like with the amount of welding I would be doing to patch, it might be easier to just order some sheet and just weld the perimeter. It would end up being an area of 15' x 7.5'.

Thoughts?
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Old 05-17-2018, 05:20 PM   #2
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You could add a second skin, but unless you can fully seal it you are begging for water to get between the two layers and rust out.

You don't have to grind the hell out of it. Just knock off the flaky stuff and treat with Ospho, then patch as normal. Prime with Rustoleum primer and call it done.
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Old 05-18-2018, 09:18 AM   #3
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You could add a second skin, but unless you can fully seal it you are begging for water to get between the two layers and rust out.

You don't have to grind the hell out of it. Just knock off the flaky stuff and treat with Ospho, then patch as normal. Prime with Rustoleum primer and call it done.
This
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Old 05-18-2018, 09:28 AM   #4
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FWIW I used this POR-15 Floor Pan restoration kit on the son's Jeep Cherokee. In my experience POR-15 makes fantastic rust treatment products and I found this kit to be no exception. It seems like this could be a great all on one solution for your rusty floor.
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Old 05-18-2018, 11:41 AM   #5
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I just wire wheel the rust then use this-


Its easy and its the BEST rust converter I've ever tried.
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Old 05-18-2018, 01:16 PM   #6
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Its easy and its the BEST rust converter I've ever tried.
Rust converter isn't going to close those big rust holes...
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Old 05-18-2018, 01:19 PM   #7
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Rust converter isn't going to close those big rust holes...
I never said it would.
I was offering an alternative to the costly multi-step process of using por15.
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Old 05-18-2018, 01:21 PM   #8
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I never said it would.
I was offering an alternative to the costly multi-step process of using por15.
I never said you said it would, so there...
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Old 05-18-2018, 01:34 PM   #9
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Originally Posted by EastCoastCB View Post
I never said it would.
I was offering an alternative to the costly multi-step process of using por15.
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Originally Posted by ComfortEagle View Post
I never said you said it would, so there...
Well I never said anything on the matter, so THERE! Either way, both products work well. The Por-15 Kit simplifies things by including everything needed, but it's certainly possible (and likely, based on the affected area) that it'd be cheaper to buy other products in large quantities. Get a gallon of Simple Green, a gallon of Rustoleum, a sealant, some primer and some sheet metal and you're good to go.
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Old 05-18-2018, 01:49 PM   #10
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Awesome- thanks for the help everyone!

The Rustoleum looks like a great option after brushing and I'll patch from there.
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