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I ordered a full set of OEM carpets and then lifted the old ones. Yikes! What do I do now? Is this the way the driver's side floor was built by the factory?
The steel floor pan seems to be covered with a mixture of different materials ranging from fairly thick hard white foam, and then various thickness (1/8" to 1" thick) foam rubber all of which was covered with a glued on thin piece of rubber-like sheet. Right now the easiest way forward (if I can remove all of the thin rubber covering) is just to apply new rubber. What do you think? Any advice greatly appreciated.
Tom
That “floor” is rubber backed foam insulation on the unibody floor. In my situation it was saturated with water and disintegrating. I made new closed cell foam insulation backed with dynamat and installed Rennline floorboards on top to level the floor again.
Consider yourself lucky. That floorboard looks pretty good. Just a bit of wear in the top, and the usual spot where the heel lies by the accelerator. I would to take a look underneath and make sure you don’t encounter what I woke up to.
But the insulation is 30 years old. Rather than cover up the lumpy mess, consider improving matters with new insulation. The Dynamat (lite) is a great start. Closed cell MLV would be the next step. Check out this RS carpet install thread. It was my 993, but same concept. The car is incredibly quiet now.
The Rennline mats is a nice way to go. But it’s easy to make your own with some plywood and a rattle can of flat black paint. There’s a photo in the RS carpet thread. Rennline was kind enough to sell me the sunken washers separately.
JamesObear that floor looks awesome, but I do want to stick with the OEM carpets. I take it you run it as-is without carpet? If you put carpets over top it looks like they might slide around on that smooth surface. Has anyone tried this?
When you say closed cell foam, do you mean something like this?
I am travelling now, but will check out your link when I return. Your pictures are very helpful and I had not heard of MLV before. All good info. I read somewhere that some folks are using a product like BlueSkin WB for sound deadening.
Looks like a small job is turning into a big job of "while you are in there". Why am I surprised?
JamesObear that floor looks awesome, but I do want to stick with the OEM carpets. I take it you run it as-is without carpet? If you put carpets over top it looks like they might slide around on that smooth surface. Has anyone tried this?
When you say closed cell foam, do you mean something like this?
Actually I have Cocoa Mats on top of the Rennline floors. You could easily run the factory mats on top as well, just need something to grip the carpet on the aluminum floors.
And yes the foam I used is exactly like that and I put dynamat on top to deaden noise/vibration as well.
Ditto. When I completely removed and fitted a new interior I pulled my floor coverings out, and yes, they were damp too (mainly drivers side). No longer fit for purpose and replaced with lighter, better sound deadening material as the above others. Originality in this instance means little, if not detrimental at worse (one big foam sponge).
Foxman, your 993 carpet install thread was very helpful. Awesome job. I will definitely take a peek at what is under the foam rubber but it feels dry to me. Car has 25,000 miles on it and was never in a winter climate, so I don't know how it could have ever gotten wet.
If I rip everything out and replace all of it with a softer product, what about gas pedal heel pressure on the floor? This area (about 6"x6") was fitted with a hard white foam board by Porsche presumable for this exact reason.
If I go with a 1/4" plywood floor, are there existing studs already there to secure the plywood? Anyone know the name of those special dished washers so I can source locally?
Cup washers… search for skid plate washers, should work.
Personally, I feel the original design sucks. The aluminum floorboards are a big improvement.
If you want more sound proofing, lay a piece of MLV bonded ccf sheet under the board, like this:
Second Skin Luxury Liner Pro - 2 in 1 Sound Insulation for Cars - Mass Loaded Vinyl and Closed Cell Foam - MLV Noise Barrier Made in USA (2 Sheets)) https://a.co/d/15LJjR9
Then tuck your carpet under the aluminum floorboard. If you carpet slips, adhere some anti slip to the mat or add some VW mat buckles….
The 2 in 1 MLV with closed cell foam that Ubipa posted is precisely what you want. Just lay it down, on top of Dynamat Lite if you like. The mats are secured by inserting a couple of Rivnuts down the center channel. There’s no channel on the right side, so the recessed washer on that side has a rubber peg underneath for support. The Rennline mats include all the hardware, but it appears the rubber peg has been replaced by a metal bracket. Hardware with Rennline mats
The 2 in 1 MLV with closed cell foam that Ubipa posted is precisely what you want. Just lay it down, on top of Dynamat Lite if you like. The mats are secured by inserting a couple of Rivnuts down the center channel. There’s no channel on the right side, so the recessed washer on that side has a rubber peg underneath for support. The Rennline mats include all the hardware, but it appears the rubber peg has been replaced by a metal bracket. Hardware with Rennline mats
My passenger side floor came with the rubber peg, but the driver side had the extra mount.
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Floor Rebuild
