Rusty GTV floorboards

[gigem75]

no sweat, you'll have it done in no time!

[daveydog]

Thanks gigem! But it's really quite daunting when one starts carving out metal from their beloved car to see what's going on underneath. I think there are some "issues" behind three out of the four quarter panels. We'll see...

[GTV-GR]

I 've got the same issue on the rear of my gtv...u do it first-i follow-post many pictures

[daveydog]

Here's an exploratory hole inthe left rear quarter panel that's just in front of the wheel:



That didn't look too good so off comes the panel:



The PO must have had the rocker panel replaced already. You can see where it's welded to the old sheet metal above the weld.
There were a lot of rusty bits of metal that I already removed but it looks like the rear of the rocker panel can be saved.



Here's the back side of the panel I just cut off. The PO or his body shop didn't do much in the way of painting the inner side to keep the rust at bay



I scraped, sanded, poked and prodded and wire wheeled the whole area. Then I sprayed metal prep over everything to kill the rust and get a good tooth for the POR 15.



There was an inspection hole in the front section of the rear wheel well so I shone my CSI flashlight in there and lo and behold, the cavity between the inner and middle sill is clean back here!
Now it's time to check out the bubbled paint on the front left panel .

[daveydog]

This is what I'm talking about:



Here's a shot after I removed the Bertone badge. Can you guess what's going on behind this panel? Maybe some type of primordeal reaction? Air plus water plus MY CAR . I'm going to re-name my baby"Bubbles"!

[Super1600]

Dave

Looks very similar to my GTV in those front sections, albeit that the bubbling on mine is definitely rust not air/reaction with fillers etc. It looks like there may be some filler on your guards and so hence perhaps the bubbling.

I previously bought the rust repair panels for the outside skin from Classic Alfa, so at least that part will be relatively straight forward. It is what is behind I am yet to find out. Undoubtedly rust, rust and more rust. Hopefully it is not going to be too tragic and expanded up into the guard etc, and ditto that the jacking point is still ok.

Your doors also seem to have the same bubbling, so I am wondering if that is also the same as your guards or more rust. If just the door skins it wont be so bad but if in the frame (as mine have) than new (2nd hand doors) might be the best option.

Goodluck with the surgery, at least it is on the way to recovery. Dave

[daveydog]

The doors are in pretty good shape actually, right side especially. The left side (driver's) door has just a few perforated pinholes. I have the doors off at the moment and the frame and drain holes are all good, just those little rust holes to deal with I'm (happy?) to say.
Since it looks like the previous owner has already done a rocker panel replacement job on this side, I'm hoping that what's behind the front left panel will be in similar shape to the left rear ie. not too bad. It's possible to replace just sections of the panel so I'll have to see what needs to be done. No turning back now! Onwards into the Unknown...

[daveydog]

After I scraped all the rust out of the area this is what I found:



Here's a shot from another angle, and this is after the PO has already had this rocker panel attended to. Probably no rust protection:



This is not a big deal. I can close off all the holes in the wheel well itself and fix the area behind the panel I just cut off. The first thing though, is to kill the rust with metal prep and then paint it with POR 15.. The inner and middle rocker panels are in good shape fortunately. This time it looks like just the outer panel behind the wheel will be replaced, that is, after I'm through welding in new bits. I want this car to survive the next 34 years.

[gigem75]

Are those your jackstands in the background

[Super1600]

Looks nasty but by now I guess you are used to it and getting better in dealing with the dreaded tin worm enemy. Must be satisfying as it is progressing.

Concur with Gigem75, I wouldnt be too keen on the wooden blocks jackstand, especially if working down and under the car.

[daveydog]

I just wish the PO had used a better body repairman. Probably a cheap fix and then sell it. Unfortunately, he sold it to me ... But I'm determined to sort this thing out and get the car back on the road.

Um yeah, about the "jack stands"...I have two proper ones on the rear axle and wooden blocks on the front lower spring seats heh heh... If my Wife finds out about this she might just push the car over on me next time I'm under there and be done with it. Thanks guys I'll definately get more support under there.

Here's all the rusty pieces I cut out:



That slit on the middle left is how a lot of the sand and debris was able to get into the cavity where the front of the outer rocker panel attaches to the middle rocker. Looks like I got in here just in time because although there was significant rusting away of the lower sheet metal, the frame rails are good. I can fabricate the missing sheet metal bits in there and then put the new outer panel on.

[gigem75]

Mine were pretty much in the same shape, With the experience you've gained so far you are cleared for take off I'll be a good feeling when you get it back on the road. It's gotten pretty cold around here so I'm pretty much at a dead end painting wise. Need to clean up the shop anyway. The painting is turing out to be more of a headache than the sheet metal but I'll get there.... someday... Keep up the good work!

[daveydog]

I'd like to be cleared for landing. Mayday, Mayday! All this rust and so little time (sigh)... Here's the bits that will be welded in:



The welding's completed. No more entry holes for water and dirt!



I sprayed metal prep over all the bare metal and then a quick coat of primer:



And finally three coats of POR 15 to really seal this area up. Fortunately, the base of the A pillar was not affected by rust, just the 20 guage sheet metal pieces. It took a few hours to cut, grind and shape the pieces but the end result is going to be a protected rocker panel.
The area between the inner and middle rockers is clean and painted so the left side is now done!

[gigem75]

Looks Great! good job! Are you getting a new wing panel? I drilled a couple of holes in the bottom of mine one one each side of the jack point and then welded there, a poor mans spot weld.

[daveydog]

Thanks gigem! If you're ever up this way it's my shout on the rum and cokes!Yes, I've already got three out of four panels because although I've only worked on the left side, I just know that the right rear panel is also fooked. Stay tuned .