Rusty Floorpan Repair

CoolAirVw · Post by **CoolAirVw** » Sat Apr 21, 2007 8:35 pm

Step 14: Since the new pan is now ready lets cut a hole in the floor.

Step 15: Trim the pan and check the fit in the hole.

Step 16: Repeat step 15 one hundred times.

Step 17: Grind the weld surfaces clean and drill some holes for "plug welds".

Step 18: Tack weld it in.

hagar · Post by **hagar** » Sun Apr 22, 2007 9:08 pm

Andrew in Flagstaff and ALL :-----you just have to admire this guy and his BODYWORK --EH. ?-----I have not seen a sight like this , since my last time in Danmark.-------Due to the TAXATION systems and SALT over there ---They (the Danes) have the finest body repair systems ---anywhere. -----In northern Jutland is a Totally modern Body Panel factory------ "Klokkerholm" ----and there is NO part of a Jetta or Rabbit that can NOT be fixed like brand new or better.---I took a look (real close) of a Mini Cooper or Austin Minni -----the guy had replaced the whole rear end ---trunk and all.--- as good as NEW----

Someone tell JACK --to start selling weld-in panels from "Klokkerholm" ---I shall tell the tale of how I found out about Klokkerholm---in my normal post.

hagar.

Buzz · Post by **Buzz** » Mon Apr 23, 2007 6:13 am

hagar wrote:Someone tell JACK --to start selling weld-in panels from "Klokkerholm" ---I shall tell the tale of how I found out about Klokkerholm---in my normal post.

hagar.

The only problem with Klokkerholm is they state they will not sell to individuals or retailers... I don't know if they would sell to Jack since he would be reselling them...

libbybapa · Post by **libbybapa** » Mon Apr 23, 2007 9:38 am

The body work looks great to me.

The only problem with Klokkerholm is they state they will not sell to individuals or retailers... I don't know if they would sell to Jack since he would be reselling them...

Then who DO they sell to?

Andrew

Buzz · Post by **Buzz** » Mon Apr 23, 2007 7:33 pm

libbybapa wrote:Then who DO they sell to?

Andrew

The only other possibility I can think of is body shops.

CoolAirVw · Post by **CoolAirVw** » Mon Apr 23, 2007 11:08 pm

Hell, I wouldn't mind being their USA distributer! If I bought 10,000 dollars worth of inventory and set up shop do ya think they would sell to me?

Buzz · Post by **Buzz** » Tue Apr 24, 2007 6:36 am

CoolAirVw wrote:Hell, I wouldn't mind being their USA distributer! If I bought 10,000 dollars worth of inventory and set up shop do ya think they would sell to me?

Only one way to find out...

hagar · Post by **hagar** » Tue Apr 24, 2007 7:20 am

Buzz said --- Only one way to find out... ????
best way is to get hagar involved ------we used to get panels ---here in the BUSH ---from BOWWOW Vancouver BC. -----made by Klokkerholm ---they made fantastic replacement strut towers.-----I am fully fluent in Danish. ----will give details in my "Normal?" post.

hagar.

CoolAirVw · Post by **CoolAirVw** » Wed May 02, 2007 8:35 pm

Finished up by treating new pan and old floor with Metal Ready then painting with Por15 grey.

Here's some pics.
New pan.

Right side

Left side

CoolAirVw · Post by **CoolAirVw** » Tue May 08, 2007 9:46 pm

Almost done with this leg of the project.

I put a bunch of seam sealer on the bottom and sprayed undercoating. It's not perfect under there but should hold water out.

I layed some dynamat type insulation. I scraped the "random cloth" insulation off the rubber "mats" and reinstalled them with the old "gatorskin" peices. The stuff I reused got the car wash and lysol treatment.

A lucky trip to the "pick n pull" yard netted a nice, clean, bright, grey complete interior out of a 91! There are four minor cigarette burns but it is a nice upgrade from the dingy dark grey (which my wife calls dirty and stinky) interior that I had. Got 4 door cards, carpet, all seats, the trim I needed for the grille and a right rear door for $150.00.

So in other words my interior will soon look nice!

After the car wash and lysol treatment to the new carpet I installed it and then installed the new seats.

Front seats & carpet (notice the contrast to the original door panels and LOOK the 91 seat has tilt

! Nice upgrade! I'll put the new door panels in soon.

Rear seats & carpet

libbybapa · Post by **libbybapa** » Tue May 08, 2007 10:03 pm

SWEET!

Andrew

Krazy · Post by **Krazy** » Sun Jul 29, 2007 7:10 pm

Check out this site.

Link to competitor removed by moderator

Hexar · Post by **Hexar** » Tue Oct 02, 2007 5:54 pm

CoolAirVw,
Very interesting posts! Thanks for sharing!

I just found out that a big portion of the floor on my Jetta also has rust, it is in front of the driver seat, where I put my left foot on when driving, and when I push that area up from under the car, I can see the floor being pushed (wiggly)

.

I am thinking to repair this (after learning how to weld of course), and I have a question for you:

where do you buy the sheet metal you used? And what is the size or thickness of the metal?

Thanks a lot!
Wenbiao

CoolAirVw · Post by **CoolAirVw** » Tue Oct 02, 2007 7:38 pm

Any hardware store has sheet metal you can use for the homemade patches.

It was 20 gauge (or maybe 22???)

Hexar · Post by **Hexar** » Tue Oct 02, 2007 8:24 pm

Thanks Richard for the quick reply!

There is a homehardware.ca store nearby, I will check it out in the weekend.

Home Depot would not have the sheet metal, would it?

thanks again!
Wenbiao

Former VWDieselParts.com Forum

Rusty Floorpan Repair

Rusty.

Re: Rusty.

Klokkerholms VW replacement panels.