Hi,

Below is my latest hairbrained idea.

The rocker panels and one of the doors on my '83 240 are rusted out -- one rocker panel really bad (gaping hole for about 15''), the door just a little bit (e.g. 1' diam hole). The body shop here says "drive it ugly". I don't know much about body repair, and don't have a welder or probably any of the other tools I might need.

I don't care too much about looks, but just want to slow the rust down a bit by keeping water out. The car is not going to last for too many more years, since the Ithaca weather is just killing the body.

I thought maybe I'd take some spray foam insulation (you know, the expanding aerosol can variety for houses). I'd fill up the rocker panels, and a tiny bit in the bottom of the door, then use a knife and sandpaper to level it out. Then coat it all with a filler-type material, then paint, then ignore for a few more years.

How bad an idea is this relative to (a) not doing anything at all, or (b) just spraying that black-tar-paint-goop stuff all inside everything?

Regards,
-Kevin