I used POR15 (an epoxy based paint) and fiberglass cloth. After grinding it down I put a rust converter on it (phosphoric acid based) and then rinsed it. After that I painted the hole and exposed metal with POR15. I cut patches of fiberglass cloth that were 2-3 inches bigger than the hole and brushed the POR15 into the fiberglass cloth until it was saturated. I put on a thicker layer of POR15 on the edges of the hole just to ensure it sealed decently. I put the POR15-soaked fiberglass patch over the hole and brushed some more POR15 over the whole patch and applied pressure on the edges. I did this until I had 2-3 layers and then got under the van to clean it up from the bottom and apply more POR15 to the edges on the bottom to give it a better seal.Whoa there JoeyB, another horror show, that looks so familiar.
I didn't grind, just scraped and beat with a ball peen hammer until I got to solid stuff.
I really liked the stick of the epoxy resin and Kevlar but what will happen with the rust entombment is an unknown. Months or years? Here's what I used plus the Kevlar. 5:1 epoxy. Takes 24 hours to get real solid at 40-60 degrees F. Much faster at higher temps.
I thought about using expanding foam but backed off so that I can monitor better.
How did yo patch the holes?
Mine were so far gone they are now locator pins for my drop in footwells. They work great for that, the slots are elongated by the rust and are now provide 'quick release.Hawk, that is some nasty doo doo. just for all the pics you deserve a thanks. I will be redoing my three spots with the POR treatment for a one and done final treatment.
The screw plugs are tough to remove, and then to reuse. Any tricks for these? Last wrecker visit I tried to carefully remove some extras for future use. The dealer would consider these sacrificial parts I assume - once they come out they are tossed.