hey Folks,
i was hearing a quiescent noise. now i found the issue.
The bold of the connectorbuffer between Frame and platform is coming out because the buffer is pushing into the platform:






this is not eanough, i found some huge holes in the loading floor!





i removed all the loose material around... worse is from downside:



anybody ever had this bad places for rust? im not sure but i think i have to remove the whole platform to restore this deep rust...
easpecially because the whole platform is bending down in the back of the car, because of the rusty connecting Points...


any other ideas?

 

If you were closer, i would recommend buying and welding in a piece of the floor from a (mostly) rust-free van from desert areas - California, Arizona, etc. I don't know if you have access to parts like this. Good luck.,...jack

 

Evidently the weather in German is the same as in Pittsburgh. Had the exact same problem.







Then used a good rustproofing under the van. That was 6 years ago. Haven't had a trouble since.

 

strange Position for rust...
my biggest Problem is the crossbeam, cause its broken. I will have to replace the whole crossbeam...
@ jack orchard, no there is no acces to those parts in Germany


are there any repairkits in USA?

 

Tough luck on that rust---sadly its almost a common thing for the E-Series. I will guess what we're seeing began inside and has worked its way out. If the original mat or rear carpeting from the manufacturer has constantly been in contact with the floor and the van is completely uninsulated that's the root cause of such damage.

The cross beams are available separately however they'd most likely have to come from the USA. Here's a parts listing for your van Toppa:




That image might not be helpful as its shown---I can crop it to show just the rear floor components if needed.

 

No need to order the cross beam from the US. Measure the old beam and take that measurements to a metal shop to have a beam built.
There's also a guy on eBay selling a whole 2008 E350 body. I just bought the leaf springs off this van from this guy.

German translation:
Scheiß di ned ei! Mess das Ding aus und lass dir in einer Schlosserei das Teil passend abkanten.
Da ist auch einer auf eBay (florianderblumen) der eine komplette 2008er E350 Hütte für kleines Geld anbietet. Von dem hab ich letztens die Federn für meinen gekauft.

 

It was a Long way to go but I finally cared for the 2 rusted beams

 

My 1992 E350 is going to be getting a very similar treatment to yours this summer. Fairly major rust holes in the floorboards.

 

I applaud you people for such a project.

But I would've just drove it or replaced it. That deep of cancer can't be isolated. The rest of the vehicle is probably questionable right?

 

Very possible the engine, drivetrain, and frame are all solid. That's the case with my van.

 

The rest of the Van is in a nice shape. The engine got only 170t KM! so about 110tMiles.


I replaced and painted the whole steering, Shocks, springs, wheels, brake lines, gas and airfilter.
Additional I isolated the whole car wth bitum mats and ,as second layer, mat of fibres. The list will be much longer but this wasnt the theme of the thread
just wanna make you sure that my VAN is in a excellent shape.
and all Jobs where done with typical german thoroughness

 

That's awesome! It's not common to see people tackle rust on this level. Definitely hoping she lasts another decade or more for you.

By the way, have you considered some kind of undercoating? Fluid Film is my favorite, you apply it liberally once a year before winter, and it seems to do a great job keeping the rust at bay.

 

im glad to hear it. Nice to see an enthusiast working on a project.

 

thank you guys.


undercoating? i used a lot of synthetic resin undercoating. will see how good it works.... used cheap stuff but a lot. if the surface is ok I tend to use normal varnish and protect it then with undercoating. As you've seen on my cargo floor. A friend of mine is selling paint in a superior Quality ;-)