Best way to repair small rust hole in floor? -
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Unread 03-07-2009, 07:27 AM   #1
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Best way to repair small rust hole in floor?

Hey guys,

I have an 86 CJ7 that I just bought and plan to herculine the tub in the next few weeks. The jeep has one small (half dollar size) hole in the driver side floor board. What is the best way to repair this? Thanks.

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Unread 03-07-2009, 07:46 AM   #2
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Is it a rust hole or a drain hole? The drain holes shouldn't be quite that big but they do make caps for them. If thats a rust hole I'd cut out all rust so you are back to just bare metal and then weld or have someone weld in a patch panel. Once that's done, prep and treat all the bare metal in that area, hit it with rustoleums hammered enamel and then herculine it.
CJ7, 258, Dana 20 T-case, Dana 30 & AMC 20, TFI Ignition upgrade, MC 2150 carb, YJ tub mod
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Unread 03-07-2009, 07:47 AM   #3
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Depending on where it's at, you might even use a hole saw to make the hole round... then just use a plastic plug in it.. a new drain hole.
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Unread 03-07-2009, 07:55 AM   #4
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The "BEST" way is to cut out the floorpan and weld in another.

Next best is to cut out around the hole and weld in a patch.

What you want to take note of in particular is how thin the metal has gotten around the hole. In general, rust doesn't just form in one tiny spot, at least not enough to make a hole. By the time a hole has formed, usually a large portion of surrounding metal has been eaten away and thinned considerably.

Cut out as much of the offending metal as possible, until you are satisfied with the thickness. Even if you are satisfied with the thicknedd, if there is surface rust, get rid of it. Grind it, wire wheel it, doesn't matter, just make sure its gone.

If you dont have a welder and don't see it buying/borrowing one as an option, consider cutting your patch 1/2 to 1 inch larger than the hole on each side, and JB weld the thing on there. No, this isn't ideal, but since the floor isn't structural (not a unibody) then all it really has to do is keep you from doing a Fred Flinstone impression. Buy some seam sealer and seal your edges.

I don't know if Herculiner is indicated for use over bare metal, so I'd like to see it primed first. An epoxy primer is best, but lets be honest, if you aren't welding a patch in, its an imperfect repair anyway. That said, you can probably get away with an off the shelf automotive primer (self-etch or other).

Just make sure your metal patch is slightly scuffed (if you dont use the etch primer) and degreased (can use acetone, laquer thinner or similar)

Good luck to you.
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