mikerajjers · Jul 15, 2020

Hi, I have been stripping my interior to give it a good clean and sound insulation. I have come across this area of rust above the passenger footwell (LHD TD5 90). Is it in need of immediate repair? I couldn't poke a screwdriver through it and there doesn't seem to be rust from the other side in the engine bay so I am inclined to think that it has rusted due to water in the footwell padding. What do you think? I am aware it will need to be sorted at some point but I want to enjoy the car during the summer. Will it be ok if I treat it with rust stabiliser and a bit of paint for now?

Gmacz · Jul 15, 2020

Rust converter and then paint.
Then just drive.

Hicap phill · Jul 15, 2020

Just check for leaves down the back of the heater causing a water trap.
Heater may need to come out to do the outer/engine bay side

potus · Jul 15, 2020

If I were a gambling man, I'd bet there's likely to be more hidden away up behind the lower dash area. I'd give it a spray with rust killer type treatment and enjoy it for the summer and have a better look at doing a repair in the winter months.

mikerajjers · Jul 15, 2020

Hicap phill said:
Just check for leaves down the back of the heater causing a water trap.
Heater may need to come out to do the outer/engine bay side

Is it relatively easy to do?

mikerajjers · Jul 15, 2020

potus said:
If I were a gambling man, I'd bet there's likely to be more hidden away up behind the lower dash area. I'd give it a spray with rust killer type treatment and enjoy it for the summer and have a better look at doing a repair in the winter months.

I think there is... I have taken a dash apart before on a 300tdi and I would rather avoid doing it again for as long as possible. I will spray some rust converter for now and paint. Hopefully it will last a year or two

Hicap phill · Jul 16, 2020

mikerajjers said:
Is it relatively easy to do?

4 bolts. As long as the captives are fine they should come out.
Normally you can see if there are any problems there.

lynall · Jul 16, 2020

Splat some pu sealant up there (5 quid toold station) paint and worry about it, if it ever fails the mot.

Discodevon · Jul 19, 2020

I had the same on mine but lower down and not as bad looking, a chap on here recommend a red oxide called tor coatings (mick 1986 I think) and the tin is stupidly heavy as it’s so loaded with zinc, anyway in two years No sign of any rust

yfo866 · Jul 21, 2020

Looks like surface rust. You'll need to find out why it's so bad, cure that then do what others have said, rust treatment and paint.
If you don't have access to somewhere nice and warm to work on it, i'd do it over the summer, not the winter, when it gets dark early, rains a lot and snows...

resto_d1 · Jul 21, 2020

Both mine and haza’s defender did exactly same. I don’t think it’s water in your padding. It will be doorseal/windscreen hinge/roof/windscreen seal/where do I stop, dripping water down and it then runs across. All the bloody way in our cases!!! I pulled my dash and welded the lot up as did he. It’s a seam and water gets in it and rots seam inside out. You can see where I’ve pryed it open here

Gmacz · Jul 21, 2020

How many bottles of beer does it take to weld up a rusty bulkhead.

Hicap phill · Jul 21, 2020

Gmacz said:
How many bottles of beer does it take to weld up a rusty bulkhead.

The more you drink the better the weld looks

resto_d1 · Jul 21, 2020

Always have a couple when welding. Steadies the hand, makes the task seem less sh1t and bud combined with burning seam sealer sniffing is a nice high

resto_d1 · Jul 21, 2020

Mine revealed more - as always does. 2 weeks into ownership too that was!!

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