Alright, so my car that i bought i thought was rust free, definitely is not. Its a 1983 300 D turbo 4 door. The passenger side floor is rusted out pretty good. it looks like the undercoating under the car failed and water got under it pretty good.
So there are not that many areas that are actually gone, maybe 1 sq. foot over the entire passenger side. the front seat mount hump is good, the back one is still good, but roughed up. There is also rust going up along the transmission hump, i have to pull the center console and drivers side apart to find what it looks like. The seat height adjuster on the drivers side is sticky.
My roomate has a welder, and hes willing to help me get it fixed, but im trying to decide what the best method for the metal would be. I can either get a new floor pan, which i haven't found a price on yet, or i can form the individual pieces i am going to need.
Also, what is the best way to remove the undercoating?
Any thoughts?
Andrew

A heat gun and gloved hands is the best way to get the undercoat off. As for the rust I would cut some panels out of a donor junk car and weld them in.

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

is there a place to get full floor pans? I am in a small college town in south georgia, there arent man donor cars around.... I might be able to find one if that is my best option though.
Andrew

Alright, so i keep digging, and the rust started under the battery tray, then went down the passenger side, got through the metal, and traveled under the car between the metal and the undercoat.
So, i am definitely going to need some repair panels. I found a source in england, is there anyone in the states who would be able to get these panels?
Andrew

I use my hand, a screw driver, and an angle grinder with a coarse knotted wire brush and it works pretty well. And you can find new panels online or you can get the from the dealer (for a pretty penny). http://www.shermanparts.com/ has what you need, although I do not have experience with aftermarket body panels, you may want to ask around. I did buy a dealer fender and it's great.

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition

thanks alot, that is exactly what i was looking for. There is a good bit of rust, and about three patch panels put into the car, so i am starting to think this is definitely the way to go.
Andrw

does anyone know what gauge the firewall is? I need to patch the firewall right under the battery tray, then next paycheck im going to get the new floor pan and rocker, have all new metal making the car ready to ride for a long time.
Andrew

wade,

sounds like my experience. read through my blog to see what you might have to do

bob