I finished up the battery rust repair on the newly aquired 240TD and thought I would share some pics. The rust had gotten behind the stabilizer bar mount and had opened a hole in the footwell also. I used 20 gauge mild steel as it had a lot of bends needed to make the filler panels. I tried to do it all in one piece, but ended up with 3 separate ones. Once everything was welded in, I used Gemplers rust converter, Eastwoods rust sealer, 3M auto body seam sealer, Duplicolor spray truck bed liner and rubberized undercoat to seal it up. Pulling the dash and A/C condensor was the worst part but the info I got here really made that possible.

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Nice work. Looks like your wagon needed you. I'm sure it will repay you by sticking around for a long time.

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Chad
2006 Nissan Pathfinder LE
1998 Acura 3.0 CL
OBK#44
"Pleasure in the job puts perfection in the work." - Aristotle (384-322 B.C.)

SOLD
1985 300TD - Red Dragon
1986 300SDL - Coda
1991 - 300TE
1995 - E320
1985 300CD - Gladys

What I would do is skip all the rubber stuff and just either wack it with bar and chain oil or a coating of grease. The problem I see with the rubber stuff is if something gets by it, the rust starts and just grows.
You could still put a coating of chain oil on it. Love the stuff.

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Currently driving a very clean 1985 300SD from the West Coast.