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Old 05-04-2003, 04:58 PM
Registered User
Join Date: Apr 2002
Location: RI
Posts: 1,040
Battery Based Water Leaks

I am doing the ritual leak repair work on my 83 300D sedan. Last summer I found a BIG hole under the battery tray or what was left of it. At the time I was so disgusted with the car all I wanted was to patch and dump it. Well, that was last year and it's sort of grown on me like a mouldy fungus. I used that spray foam in a can to try and patch it up. Glommed it in there then trimmed it back so I could get the battery tray back in. I'd like to make it a little more waterproof. Do you think covering everything with a couple of layers of good duct tape would do the trick? Removing the spray foam seems pretty impractical. I am thinking of using the duct tape then spraying it liberally with the stuff that's sold as a leak stopper for pipes. I know the crap doesn't work with pipes but I'm hoping it'll do an ok job for this area. Anyone had any luck patching up this area? Real tough, lots of wires going through and hard to get at too. Thanks for any advise.

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Old 05-04-2003, 05:52 PM
Join Date: Jul 2001
Location: Old Lyme, Connecticut
Posts: 3,596
I just purchased a kit from POR 15 to deal with a rust problem in my brother in law's van. I have yet to use it but I also bought some materials to repair some rust around the jacking tubes on the 240D. I will be using that in the next week or so, after my daughter brings the car home from college.

This stuff supposedly cures to be impervious to rust and water. You may want to give it a try, just paint the stuff over what you have. Good Luck, Jim
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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Old 05-04-2003, 07:04 PM
dmorrison's Avatar
Registered User
Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,694
How big is the hole???

POR-15 is good stuff. Used it on my sons 65 Mustang.
You need to go to the POR web site

Consider buying some POR and/or the putty. Or epoxy. You MUST follow their directions and use their products in the order they say or it may not adhere and do the job.
Marine Clean, then Metal Ready, then the POR-15. Get the sovent you'll need it or you can use 3M weatherstrip adhesive remover.
They also have a fiber mesh that can be layered like fiberglass and POR'ed over.

CAUTION If you let the POR-15 dry on your skin, You can not get it off and it will have to wear off ( usually about a week) . If wet the solvent or 3M remover will take it off. Cover yourself completely before painting with it.

1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car
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Old 05-04-2003, 10:38 PM
Registered User
Join Date: Nov 2002
Location: Wakefield, RI
Posts: 2,145
I will also recommend POR15. They sell a starter kit with a small amount that may or may not be enough for your repair. I would wire-wheel the damaged/rusted area around the hole with the sprayfoam in place. Try sanding/contouring the foam to match the firewall. POR15 the newly cleaned metal surrouding the hole and let it cure. Then I would lay 6 or 8oz fiberglass cloth (not mat) over the area overlapping the metal at least 1/2" on each side of the hole, and saturate with epoxy resin. I would go to West Marine, etc. and use West System resins. They are very high quality but not exactly cheap. It will make a much more permanent repair than duct tape.... I am local to you and more than happy to take a look at it if you are interested. RT

When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K
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