It appears that rust has gotten the better of my 87 740 sedan. There is a large 'wound' on the driver's side directly under where one's left foot would rest. The 'gash' is about 6 or 7 inches (10-15cm) long and 0.5 inches (1 cm) wide. I poked my finger in there and could feel the bottom of the carpet.

Does anyone have cheap, effective, simple repair ideas?

Thanks!
Caleb in Massachusetts
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⏣ 740 GLE, 85 BMW K100]

Check out this site and it will tell you more about the suppliers:

https://www.por15canada.com/can/dealerlist.htm

or check out their website:

www.por15.com

for order information.

Tim

On my '86 740 I used the POR-15 Trunk and Floor Pan repair kit and it worked fairly well. Just make sure everything gets really clean and free of debris before you paint. Instructions are pretty thorough. Also, be sure to protect yourself against getting paint on your skin; it doesn't come off for weeks. I got a nice blob on my bald head and it looked like I had leprosy or something.

Good luck.
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Darius in Albany NY '86 744 GLE (172K); '91 745T (161K)

Darius,

You could say that you were the first to try on that spray-on hair stuff!

What is this POR-15 Trunk and Floor Pan repair kit? Is this a volvo part or an Auto Zone type thing?

Thanks
Caleb
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⏣ 740 GLE, 85 BMW K100]

Thank you all for the ideas! Now if only my execution is successful!
--
⏣ 740 GLE, 85 BMW K100]

I had the same problem on my brick on both sides. The issue I had was that in rain or snow teh rugs would get soaked from crap shooting up in the wheel wells. My solution was as follows:

1) Put the car up on ramps

2) Using pliers, metal cutters, and a sander with 60 grit or less cut/sand/or snip all bad metal you can get off. Get as much of the bad metal off as possible.

3) Once you have it all out mix some hardening compound (I prefer non-fiberglass because its easier to deal with, but fiberglass is stronger), and paste the compound on from teh bottom. The rug will serve as a backboard to paste against and allow you to smear a solid layer on.

4) Apply the first layer, wait for it to dry, and apply another layer.

Problem solved for me.

good luck,
rt

I had that probem on both sides. There is some discussion about water originating from above the problem (but not from wet boots etc.) It is a design defect, I suspect. I screwed some sheet metal in there and then got fiberglass repair (the can with the goo and the sheets of fibergalss) and applied it below the metal and above. I think mine was leaking at those weird rectangular black plastic access plugs about a foot above the deck. If you pry them out for inspection they just break apart. I would just goo them over. I also silicone caulked the split sheath that leads wires into the car near the door hinge. The water comes to rest beneath the rubber floor and has almost no way to evaporate back out. I'm not getting any more water in there now.

Remove the carpet. Remove all rust on the top (try the POR-15 series of products), then weld a steel plate over the hole. Paint carefully.