In the classic "since I'm there"...I had to remove the interior to get at my tranny, so decided to wheel the (very small) amount of visual rust and Bedliner the interior
The rust isn't bad, only a few dime sized holes have appeared where the PO used bondo, otherwise it's a very solid floor
I'm not in any mood to do really intense sheet welding (all the holes are on corners, etc) for what little rust there is.
Do you guys have any thoughts on bondo, glass, or other? Because the holes are so small I guess I do have the option of welding in some little 'plugs' instead of making complex pieces...
I Used USC Duraglass(supposedly waterproof) for small holes. the problem with welding them is that if its rusted out. as soon as you apply the heat ,the hole will just grow and grow. could put a metal patch over it but it will trap moisture and rust worse . just my 2cents.
Cut and weld is always the best repair. Even with small holes, you should try to cut back to good metal and weld in a patch.
Repairing rust in corners is even more important because it can spread from one panel to an adjacent panel very easily (they don't call it "Cancer" for nothing).
If welding is not an option for you, sanding and treating the rusted area is probably the next best thing. There are some pretty good rust treatments out there. Bondo will work for small holes, but you will want to add something to reinforce the patch for anything over 1/4 - 1/2 inch wide (a lot of people use a piece of window screen). I've also seen people use JB Weld or similar epoxy mix to plug a hole.
Make sure to protect your repairs with some good paint and maybe some undercoating too (there are mixed opinions on undercoating, but I personally believe it helps protect the undercarriage from rock chips).
Wire wheel the rust out as best as u can and use what was previously mentioned or EVERCOAT's metal to metal. It is a metal reinforced filler that will not let rust come through. Sand smooth and paint or bedliner will finish it off. Obviously patching it in would be the best way to go but if u don't want to get in to all of that, this way is good too.
Duraglass is good. It's strong & doesn't absorb moisture. Need to follow up with some decent etch primer/epoxy primer. Some por15 is a good fix also, little pricey but durable, &there are similar products at a bit lower price.
The problem with glass or other fillers is the backside is exposed still unless the OP does both the interior side of the tub floor and the bottom, where the most exposure to the elements is.
that's a good point
i think i've decided to just do some good quality filler (kitty hair, evermetal etc.) and bedline the interior, and rubber paint the bottom side of the repairs. there is very little rust on the body and at this point i'm not ready for body restoration, i'd like to get the mechanicals working and this darned heep on the road!