Def 90 Rusty Footwells

Chris95 · Jan 4, 2022

I've a rust hole in my footwell right under the accelerator pedal. Panels aren't very expensive so I'm wondering whether to replace the full panel or get it welded. Plenty of time but have not done this one before and not sure how much effort it is and whether it is better to replace or have it welded.

Any thoughts?

miktdish · Jan 4, 2022

Depends what the rest of the pedal box is like, ie how much rot there is.
Pull all the carpets out and take off the A pillar covers etc. removing the tunnel will also give you a good 'view' of the area,

A repair panel isn't that expensive although cutting out, fitting and welding in is more than a mornings job ... https://yrmit.co.uk/product/rhs-extended-footwell-repair-panel-lr-defender/

chrisstdt · Jan 4, 2022

Just had the same dilemma with mine

I decided to just patch it as it was only a small hole (atleast it was when I started ! )

Ended up with several large patches and struggled as remaining metal was so thin

Give it a good poke from both sides and if in doubt buy a whole footwell and do the job right

v8250 · Jan 5, 2022

@Chris95 , unless just wanting a quick/cheap repair and/or it's only a small hole...it's always best to replace the whole footwell. As above, buy from YRM as they are good quality panels of correct thickness and fit first time. Replacing the complete footwell also enables you to give the A-pillar, floor and surrounding area a good inspection, complete any remedial repairs and give a thorough clean up. You'll need to remove the right hand wing for proper access but this is easy/only a few rusty bolts...

slomofo · Jan 6, 2022

There is a cut down version that replaces the rotten bit without having to cut out the whole footwell - cheaper and quicker. Done both of mine, seam sealed and riveted.

https://www.ebay.co.uk/itm/373413981791

Worth a look, they were a perfect fit….

lynall · Jan 6, 2022

slomofo said:
There is a cut down version that replaces the rotten bit without having to cut out the whole footwell - cheaper and quicker. Done both of mine, seam sealed and riveted.

https://www.ebay.co.uk/itm/373413981791

Worth a look, they were a perfect fit….

Like it, I made the same years ago out of 2mm alloy sheet for my 90, not as smart as the ebay ones mind!

potus · Jan 8, 2022

As others above have said, if you've found a rust hole large enough to need welding it is highly likley there will be more in the vicinity.

Have a real good look and poke around before patching.

Defender's are rusty things

Def 90 Rusty Footwells

Chris95

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miktdish

Guns n Chainsaws

chrisstdt

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v8250

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slomofo

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lynall

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potus

Well-Known Member

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