240D Floor Pan Rusted Through ! - PeachParts Mercedes-Benz Forum

sgoodhart · #1 06-13-2002, 08:16 AM

I have a 1981 240D and noticed that the passenger side front floor pan has now rusted through. Can anyone give me ideas on whether it is feasible and the cost to repair this. Also, what type of repair facility would do it ? My son uses this car and I would like to try to get a few more years out of it while he is in school. Thanks.

JPL · #2 06-13-2002, 08:41 AM

Hello:
I was faced with a very similar situation, but it was driver's side rear pan , in a 123.

My mechanic sub contracted the job out to a body shop he trusts. They did an okay job, albiet a bit rushed looking at close inspection underneath. The job cost about $250. But after looking at it, you can definatly do it yourself, if inclined. I am sure cost also depends of the severity of the rust. Mine was a corroded (sp?) area about 4" around, nice view of the street when the carpet was lifted.

File, sand or cut out the really rusted area.
get some screening or solid sheet from an auto-supply.
under body putty and the like, I have a product called POR-15. they also sell a rust inhibitor and chassis-black product. It is fairly easy stuff to do. I am skipping alot, but do a search and I am sure you will get more complete advice than I am giving here. But if you have the time, its kinda easy.

Hope this helps.

James

sgoodhart · #3 06-13-2002, 12:21 PM

Thanks James. I will definitetly take a look at doing it myself. I just hope the whole floor pan is not bad.

Scott

JPL · #4 06-13-2002, 02:00 PM

Scott;

Just a thought: Chock the wheels, raise the car, and do most of the patch work from under. I found that to be a little easier. Clear and clean from the top, patch from underneath. You may want to wear saftey goggles, latex gloves, and an air filter mask becasue of all the rust flakes and stuff. Plus, the chassis-black and rust preventatives can be noxious.

Just my $.02.

Lemme know how it turns out.

l8r,
James

sgoodhart · #5 06-13-2002, 05:25 PM

Thanks James for the tips. I'm going to look at it again tonight and see if it looks repairable or if I need a whole new pan put in.

Scott

#6 06-13-2002, 07:35 PM

If it's a small spot (no seats attached to it, etc.), you can just rivet in a piece of sheet metal and it will last several years. Don't get confused about totally re-doing the body, if you just want a couple more years out of the car. There's a big difference between taking a car back to new-condition and just making a "usable" car.

sgoodhart · #7 06-14-2002, 10:55 AM

Thanks Ron. I looked at it last night and the rust is pretty bad in a fairly large area. It is actually under the front seat where it attaches to the floor. I am just interested in putting it in useable condition so someone does not fall through ! I am going to see if I can find someone in the Raleigh, N.C. area that can cut out the rusted area and weld in some sheet metal.

Scott
1981 240D