Floor pan Rust damage - TCCoA Forums
 
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post #1 of 17 (permalink) Old 08-08-2015, 04:34 PM Thread Starter
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Floor pan Rust damage

How bad does it look? Will the rust damage greatly weaken the structural integrity of the car. Hopefully I can fix it without too much cost or I might just habe to stop putting money in this car and just drive it till the wheels fall off. Scroll through the pics I had trouble copying the links for the pics cause I'm using my phone.


Last edited by Rodeo Joe; 08-09-2015 at 04:54 AM. Reason: Added picture
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post #2 of 17 (permalink) Old 08-08-2015, 04:50 PM
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post #3 of 17 (permalink) Old 08-08-2015, 06:14 PM
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Is that carpet showing through metal? Wow it looks bad.

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post #4 of 17 (permalink) Old 08-08-2015, 06:47 PM
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Only one picture shows up, and there is no way to accurately gauge how bad the rust is based on that picture. A lot of times someone will damage that area while jacking the car up, which allows rust to start forming, so it may be only a small patch needed. Alternatively, that could be where the water pooled inside the car and where it rusted through, but the entire rest of the floor may be paper thin. The only way to tell for sure is to pull the carpet up and see what the floor looks like from inside.

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post #5 of 17 (permalink) Old 08-08-2015, 07:23 PM Thread Starter
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OK I'll take the carpet out soon. Here's another pic.






Last edited by Rodeo Joe; 08-09-2015 at 04:59 AM. Reason: Added pictures
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post #6 of 17 (permalink) Old 08-09-2015, 05:00 AM
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Kevin,

I added the images for you.

Good luck!

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post #7 of 17 (permalink) Old 08-09-2015, 12:20 PM
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Looks like somebody used those spots to jack it up and the crumpled area eventually started rusting up. I'm no expert but I don't think that area is crucial to the structural integrity of the car. If it were mine I'd probably clean it up the best I could from beneath and up top, coat it and then patch it up. If it is structural then probably weld in a peice. It does look relatively rust free otherwise.
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post #8 of 17 (permalink) Old 08-09-2015, 03:29 PM
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I was going to say, the rest of the pans look spotless. I'm not so sure this is a jack damage issue though, A. because it's not a jack point and when misused as such it ends up way more deformed than what we're seeing, and B. the corrosion looks more prevalent inside the holes. If you have any water leaks it will usually puddle up in that channel area of the pan, I'd say it's definitely repairable, but I'd look for the source of the leak to prevent from reoccurring.

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post #9 of 17 (permalink) Old 08-09-2015, 05:31 PM Thread Starter
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post #10 of 17 (permalink) Old 08-09-2015, 05:32 PM Thread Starter
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post #11 of 17 (permalink) Old 08-09-2015, 06:07 PM
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FYI, if you copy the text in the box marked "IMG" on photobucket, and paste that text here, it will insert the picture in the post. As for your rust, it isn't structural, and it certainly can be repaired, but it will be very time consuming to do it right because you will need to grind out the seam sealer on the outer edge, then drill out all the spot welds there to separate the floorpan, then you will have to make a patch panel and weld it in, then redo the seam sealer and repaint it on both sides.

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post #12 of 17 (permalink) Old 08-09-2015, 09:27 PM
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Originally Posted by XR7-4.6 View Post
I was going to say, the rest of the pans look spotless. I'm not so sure this is a jack damage issue though, A. because it's not a jack point and when misused as such it ends up way more deformed than what we're seeing, and B. the corrosion looks more prevalent inside the holes. If you have any water leaks it will usually puddle up in that channel area of the pan, I'd say it's definitely repairable, but I'd look for the source of the leak to prevent from reoccurring.
The second pic he posted looks like the front of it was caved upwards which is why I said that. But you're right, definitely looks like it started from the inside now that we have some more pics.
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post #13 of 17 (permalink) Old 08-09-2015, 11:51 PM Thread Starter
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Thanks everyone for helping out. I was thinking about brazing it with a gas welder since the metal is thin. I can try to use a Tig welder but I'm not that good with it. Should I just bring a gas welder to a junkyard a use a cutting torch and use that as a replacement or just use sheet metal? And I found 2 cracks under the rear shock bolts on both sides, can I use wire brush bit and weld it back together? I need to buy a gas welder so I can start this project. I can't believe all the rust I found.
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post #14 of 17 (permalink) Old 08-10-2015, 07:53 AM
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Now, those rear ones - I'd take a good hard look at those. They're support points and take a LOT of jolting, so I'd read the re-enforcement threads on here and decide if it's worth it or not.

My take is no, but then, this isn't the rust belt either.

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post #15 of 17 (permalink) Old 08-10-2015, 02:15 PM
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Wow!..

You wouldn't think there would be cracks near the shock towers on a 1989 Base Thunderbird..

Judging by the rust on the rest of the car..Maybe the rust compromised it structurally enough to start causing cracks in that area..

Is the X-Brace still installed behind the back seat cushion?..Is the X-Brace broken?


At this point in the cars life it doesn't really owe anyone anything..You might as well just continue using the car as is, and forgo repairing any of that rust..

IMO..The body is too far gone structurally to attempt any restoration, or rust repair..

I would just continue maintaining it mechanically, and drive it until the transmission dies..





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post #16 of 17 (permalink) Old 08-10-2015, 02:30 PM
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Yeah there's not really a cost effective way to fix those towers properly, simply welding the crack isn't going to be permanent since the steel around the weld is now weakened. It doesn't really surprise me it's an 89 base with this, Ford made some very substantial revisions to the rear wheelwells/towers in 93(benefiting from the FN10) and by and large those stress cracks I see or hear of with these cars are concentrated to 89-92s. It was definitely an observed problem by Ford

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post #17 of 17 (permalink) Old 08-10-2015, 04:01 PM Thread Starter
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Yea the x brace is completely broken. I guess fixing this car may not be such a good idea, I just got to drive it slow around corners so the car doesn't break in half. I didn't see any cracks on the outside where the inside ones were, so hopefully this car might last a few more years while I save some money for a different car. If I do get another T-Bird I would only get a 96/97 V8 since those ones would have the least problems.
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