Cleaning Rusted Floor Pans: Diy Guide To Restoration

Rusted floor pans can be a pain to deal with, but there are several ways to clean and restore them. The first step is to remove any loose rust and flaked paint with a wire brush, sandpaper, or steel wool. Then, you can use a rust converter or remover, such as naval jelly or vinegar, to get rid of the remaining rust. If there are holes in the floor pans, you can patch them with new metal or a fibreglass mat and resin mixture. Finally, the floor pans should be painted with a rust-inhibiting primer and paint. Some people also recommend using a product like POR15 to treat and prevent rust. While welding in a new floor pan is often considered the best solution, there are also temporary fixes, such as using construction adhesive, roofing cement, or body panel adhesive to attach a new piece of metal over the rusted area.

Using a wire brush

Start by removing any loose rust and debris from the floor pan using a stiff wire brush. This will help you assess the extent of the rust damage and create a clean surface to work with. If there are any large rusted areas, you may need to use a wire brush attachment on a grinder to quickly and effectively remove the rust. This process will create a lot of dust and debris, so it is important to work in a well-ventilated area and wear a respirator to protect your lungs.

Once the majority of the rust is removed, you can switch to a finer wire brush or wire wheel to get into tight spaces and remove any remaining rust. Take your time with this step, as you want to remove as much rust as possible. After brushing, you can also use a rust converter or naval jelly to treat any remaining rust and prevent it from spreading.

In addition to the wire brush, you may need to use chemical treatments, such as lacquer thinner or brake clean, to remove stubborn rust and prepare the surface for painting. Once you are satisfied with the level of rust removal, it is important to clean and degrease the floor pan thoroughly to ensure that any coatings or paint will adhere properly. This can be done with a degreaser or a mild acid solution, followed by a thorough rinsing and drying.

After the floor pan is clean and dry, you can apply a rust-inhibiting primer or coating, such as POR-15 or Rust Bullet, to protect the metal and prevent future rust. Multiple coats are usually recommended, and you may need to sand between coats to ensure proper adhesion. Finally, you can apply a topcoat of paint in your desired colour to complete the restoration.

Sanding and priming

Sanding:

• Start by removing any loose rust and debris from the floor pan using a wire brush or a conditioning disc. It is important to get down to clean metal and assess the extent of the rust damage.
• For larger rusted areas or complex stampings that are challenging to replicate, consider purchasing a partial floor pan. You only need to use enough of the replacement pan to cover the rusted section.
• If you're welding a new patch or replacement panel in place, ensure you trim and fit it carefully. This step is time-consuming but ensures a better final result.
• Before welding, consider using a rust converter or a product like POR15, which is activated by rust and helps prevent further rust spots.

Priming:

• Once the rusted area has been sanded and prepared, it's time to prime the surface. Choose a primer suitable for metal surfaces, such as an epoxy primer.
• Ensure the surface is completely dry before applying the primer.
• Apply at least two coats of primer, allowing each coat to dry thoroughly before applying the next.
• Lightly sand the first coat of primer before applying the second coat to create a good key for the paint to adhere to.
• After priming, you can fill any remaining pin holes with fiberglass filler to keep moisture out and ensure a smooth finish.

Remember, repairing rusted floor pans can be a time-consuming process, but taking your time with the sanding and priming steps will pay off in the long run.

Using baking soda

Baking soda is a great option for cleaning rusted floor pans as it is a base strong enough to dissolve the rust and it also has some abrasive properties. Here is a step-by-step guide on how to do it:

Step 1: Prepare the Baking Soda Paste

Mix equal amounts of baking soda and water to form a paste. You can adjust the consistency by adding more or less water as needed. The paste should be thick enough to adhere to the rusted areas.

Step 2: Apply the Baking Soda Paste

Using a brush or sponge, apply the paste generously to the rusted areas of the floor pan. Make sure all rusty spots are covered with a thick layer of the paste.

Step 3: Let it Sit

Let the baking soda paste sit on the floor pan for about an hour. During this time, the baking soda will react with the rust, helping to dissolve it and loosen its grip on the metal.

Step 4: Scrub the Rust

After the waiting period, use a scouring pad or a metallic scouring pad to gently scrub the rusted areas. Keep the scouring pad wet to avoid scratching the metal surface. If necessary, add more baking soda paste to the areas that are more heavily rusted.

Step 5: Rinse and Dry

Once all the rust has been removed, rinse the floor pan with water to remove any remaining residue. Dry the pan thoroughly with a clean towel or cloth.

Additional Tips:

• For more stubborn rust, you can try using a thicker paste or letting the baking soda sit for a longer period before scrubbing.
• Always wear gloves and protective eyewear when working with rusted metal to protect your hands and eyes.
• Baking soda is a mild abrasive, so it is important to test it on a small area first if you are concerned about the finish of your floor pans.
• To prevent rust from forming again, apply a layer of oil to the metal surface and store the floor pans in a dry place.

Using vinegar

Vinegar is an effective way to clean rusted floor pans. The acetic acid in vinegar dissolves and removes tough spots of rust from your pans. Here is a step-by-step guide on how to use vinegar to clean your rusted floor pans:

Step 1: Prepare the Vinegar Solution

Fill your sink or a large container with equal parts white vinegar and water. Ensure you have enough of this solution to completely submerge the rusty floor pans.

Step 2: Soak the Floor Pans

Completely submerge the rusty floor pans in the vinegar and water solution. Let the floor pans soak for at least one hour. For severe rusting, you may need to let the pans soak for up to eight hours. Check the pans every 15 minutes to see if the rust is easily flaking away.

Step 3: Scrub the Pans

After soaking, remove the floor pans from the solution and use a scouring pad, scrub brush, or steel wool to scrub away any remaining rust. Scrub along the grain of the metal to prevent new scratches from forming. For more delicate surfaces, use a softer cloth or paper towel to rub away the rust.

Step 4: Rinse and Dry the Pans

Rinse the floor pans with warm water and mild dish soap to remove any remaining vinegar and rust residue. Dry the pans thoroughly with a clean towel. You can also place the pans on a stovetop over low heat to ensure they are completely dry.

Step 5: Re-season the Pans (if necessary)

If the floor pans are made of cast iron or carbon steel, you may need to re-season them after cleaning. Coat the pans with a thin layer of cooking oil, such as vegetable oil, and place them in an oven preheated to 350-450 degrees Fahrenheit for about an hour. This will create a protective layer that helps prevent future rusting.

Using a rust converter

Rust converters are a great option for treating rusted floor pans. They are activated by the rust itself, so it's important to not remove all the rust before application. Here is a step-by-step guide on how to use a rust converter to treat rusted floor pans:

Step 1: Remove Loose Rust and Degrease

Use a wire brush to remove any loose or flaking rust from the floor pan. You can also use a wire wheel or cup attached to a grinder for larger areas or a wire brush in a drill for hard-to-reach areas. Once the loose rust is removed, degrease the area with a suitable cleaner to remove any oil, grease, or wax.

Step 2: Apply Rust Converter

With the surface prepared, you can now apply the rust converter. Follow the manufacturer's instructions for application, ensuring that the metal surface remains wet during the process. Allow the rust converter to cure, following the specified time and conditions.

Step 3: Sand the Surface (Optional)

If the rust converter has dried completely, you may need to sand the surface lightly with fine-grit sandpaper (e.g., 300-grit) to create a better adhesion for the next coat.

Step 4: Apply a Second Coat of Rust Converter

Apply a second coat of the rust converter, following the manufacturer's instructions. This second coat will provide a stronger barrier against rust and ensure complete coverage.

Step 5: Patch and Paint

After the final coat of rust converter has dried, you can patch any holes with a suitable filler or weld in new metal if necessary. Once the patches are complete, apply a primer and then a couple of coats of paint to the floor pan for added protection and a finished look.

Remember to wear the appropriate safety gear, including gloves, eye protection, and a respirator, when working with rust converters and other chemicals. Always work in a well-ventilated area and refer to the specific product instructions for detailed application guidelines.

Frequently asked questions