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Old 01-02-2021, 09:46 PM   #1
Join Date: Aug 2020
Location: Austin, TX
Posts: 12
Year: 2002
Chassis: Chevrolet Express G3500
Engine: 6.5 L Turbo Diesel
Rusty corrugated floor

Our cutaway shorty floor has rust, which was not too surprising. What was surprising is that the floor is corrugated metal. After some research, I found out itís rare but not unheard of.

Plan is to rivet or weld new corrugated metal in the rusted through sections. Do rust converter for all other sections after wire brushing down to metal. Then use Rustoleum or rust encapsulator and seal edges. Any suggestions or tips?
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Old 01-03-2021, 06:55 AM   #2
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Join Date: Jan 2019
Location: Philadelphia
Posts: 7,011
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
I wouldn't put a whole lot of elbow grease into wire brushing the rust - just scrape any loose bits off and let the Ospho (or whatever rust converter you use) do the real work.

Welding patches is best since it leaves no further holes in the floor, but you could also use self-tapping screws which would be lot easier than riveting (and would require no special tools except a drill).
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