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240 Rust in floors. What should I do?

sloopy

2-digit whp
Joined
May 25, 2020
Location
North Texas
I have some rust in the floors of my 240. Behind the front drivers seat, there are two full on holes which ive scrubbed and treated with ospho a long time ago. In front of the front seats on both sides, I have what looks like two very bad rust spots which can be seen from under the car and it's along a welded seam. Do I need to cut all this out and have someone weld some patches? Or is this not necessary? I'd like to do the right thing. Especially because I'm about to put sound deadening all over the floors. What do yall think?

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The right thing is to cut it out and replace with good steel.

The Red Green way is to wire brush it, encapsulate with por15 and fiberglass patch it.

The Tbricks way is to slap on a double layer of sound deadening and put two 15's in the trunk......
 
I have some rust in the floors of my 240. Behind the front drivers seat, there are two full on holes which ive scrubbed and treated with ospho a long time ago. In front of the front seats on both sides, I have what looks like two very bad rust spots which can be seen from under the car and it's along a welded seam. Do I need to cut all this out and have someone weld some patches? Or is this not necessary? I'd like to do the right thing. Especially because I'm about to put sound deadening all over the floors. What do yall think?
The first couple spots aren't bad. Should be easy to cut back to clean metal and weld in small patches. With the larger bits from underneath and poking up into the interior I'd wager more is hiding.

Cut it out, weld in new, POR 15 for safety. It is a floor patch that is relatively small, so pristine welds aren't really needed, just solid and not porous.
 
Regarding ignoring a problem... I still recall the small paper sign attached to my dentist's light, when I was a wee tad...

"The 5 most dangerous words: Maybe It Will Go Away."
 
American body shops are mostly not on board with rust repair. The few shops that are out there that will do metal work all want it to be a 200k$ Porsche so they can make a lot of money to send their children to college. Volvo rust repair is for DIY. You can do it. Instead of POR15 I would try some of the fancy new encapsulator stuff from Eastwood. My friend just used it on his Amazon floor and it worked great. Making it go from porous with holes to solid floor. Good stuff.
 
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