Car in question is the 220d.

There are rustholes on the floorpan. What is the best way to deal with this? My biggest fear is the whole driver's seat falling through the floor.

It is pretty bad. When I raise the car using a floor jack, I see 'rust flakes' on the jack after I use it.

Is the whole floor pan replaceable? I don't weld so is this a big deal to do?

I think if this rust issue is dealt with, it could add another ten years to the car. Not dealt with, the car might only have a couple left before safety issues become a problem.

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Ben
1987 190d 2.5Turbo

Best way is to weld...

Look round local bone-yard, and cut out a complete good floor-pan, and have a chat to a local welder to repair. This would be the best way to do it....

Alternatively, it could be patched up depending on how bad it is....

Check also, where the floor-pan meets up to thge rear spring-perches under back seat and inner rear wheel arches...

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http://i190.photobucket.com/albums/z...0TDnoplate.jpg

Alastair AKA H.C.II South Wales, U.K. based member

W123, 1985 300TD Wagon, 256K,
-Most recent M.B. purchase, Cost-a-plenty, Gulps BioDiesel extravagantly, and I love it like an old dog.

W114, 1975 280E Custard Yellow,
-Great above decks needs chassis welding--Really will do it this year....

I had an old school body man patch some floors of my 78 Datsun Z (they're much more rust prone). He cut out what was needed & formed, welded the replacement panels then applied body sealer. I prepped the new metal & applied POR15. You can hardly tell they're patched and I also don't remove the carpet to just see what nice floors I have. Paid $300. You need someone that likes to fab stuff, not a parts changer. Try the people that fool with street rods.

When you use the floor jack, where are you putting it to lift the car?

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1981 300TD "The Green Lantern"
1980 300TD
1983 300D Euro "China Cat"

right over the 'jacking hole' thing

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Ben
1987 190d 2.5Turbo

on my 240D, i had to order complete pans (somewhere out of michigan, parts & shipping alone ran me $300, and then approx another $800 in labor to remove of the old stuff! )

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Matthew McIvor

2016 E350 4Matic Black/Black
2007 GL450 4Matic with Off-Road Pkg Silver/Black
1995 E300 Diesel White/Gray
1994 S600 Euro Black/ Black Velour
1986 560SL Blue/Blue/Gray
1986 190E Blue/Blue 93k

and how did it turn out? you reused the carpet and everything? does it look ok?

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Ben
1987 190d 2.5Turbo

Ben, I would take a close look at your rocker panels too if there are rust flakes coming off around the jack points. Look for cracked undercoating on the outside and pull the side carpet up a little on the inside.

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1981 300TD "The Green Lantern"
1980 300TD
1983 300D Euro "China Cat"

i'm afraid to! i might cry!

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Ben
1987 190d 2.5Turbo

If you are not sure someone should establish the extent of the rust. It may not be too bad in your geographical area. There is a type of rusting that weakens everything for example. That type also tends to be well spread as well.

Occurs more in the rustbelt areas. Perhaps your floor pan rust is limited from water leaks for example instead. It is a good sign you can still use your jackpoints in my opinion. Serious structural type rusting is the killer in my opinion as well.

I would almost change the engine etc over into a rust free body before tackling extensive rust work on a 123 car. If limited to a few floor pan patches it is doable though. What is considered bad rust in one area of the country may be in reality very little in another or vice versa.