PorscheDoc

Get some aluminum sheet, cut it to size, form it over the entire area, rivet it in place, coat the edges with seam sealer, then por 15.

FRporscheman

Hmm... didn't think of that. How do you recommend I form the aluminum?

Would it be worse if I cut out the rusty tray, put in a steel sheet, tack-welded the edges (I'm afraid I'll burn right through if I go full welds) and then do the seam sealer and paint/por15/rustbullet?

PorscheDoc

Hammer, pliers, etc. My box was so bad you could stick your hand through it. Hasn't leaked since.

dontnow

You will burn through or warp the panel if you try to do full welds. The key is to either weld 1/2" then go oposite and do 1/2" and work your way around, or 1 million tack welds.

odurandina

btw, don't forget this one the next go-round..... not a penny over 2 grand.



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FRporscheman

Well I decided to try the por-patch first. I've just heard so many good things about por-15, I figured now is a good time to finally try out one of their products for myself. If it doesn't hold up, I have lots of other great options to pick from thanks to you guys.

I'll post pics and report the results.

AScholtes

Good luck... I myself (I know several others) have never had Por-15 do anything for rust and protecting from future rust. This is why I recommended RustBullit. I Have read and seen the pictures in magazines of Por-15 treated panels that are rusted on the treated panels and have seen it first hand myself. Hopefully it works for you, but I have a feeling you will get the same results as I and others have.... good luck

jason952

I used por15 and fiberglass tape, worked well for me, same problem, then switched to a gel cell battery

Paulyy

just to keep things clear. Rust and Cancer are pretty much the same. Once it's there it'll just grow bigger. If removed and still traces are left behind it'll grow again. Once it's 100% gone it's gone for ever.

ernie9468

Arash __After your done with the repair may I suggest you get a (battery matt) had one in my 944 for yrs & planning on getting one for my 968.It will absorbe the moisture & any accidental battery leak, for those out there which haven't got one they sure worth the money .My ex 83 has a perfect battery tray without any rust what so ever.

snakoil

been there, done that
I got my body guy to put a new sheet metal...only downside is that my heater core is still not back in the car after 7 months....weight loss baby! :P

FRporscheman

AScholtes, I hope it works for me, but if it doesn't I think the next thing I'd try is to cut out the metal, rivet in a new sheet, and seal it with rustbullet.

I applied the por-15 today. If anyone is wondering, it has the consistency of whipped cream. I thought it would be thicker, like silicone or urethane, but then again they do state it's just a thickened version of por-15 paint. Still it smeared on alright and white it was tricky closing the bigger holes in the metal, it did close them. I'll let it cure for a couple of days and take a look at it then.

Ernie, I've never heard of a battery mat, seems like a good idea. Does one need to replace it periodically?

Perculator00

Arash,

Did you end up completing the process w/POR-15?
If so please post some pics. I just pulled out my battery over the weekend and noticed rust buildup and a small hole near the front. I am debating on what to use, but first need to scrape down/wire brush to safe metal.