Rusted through! (PICS)
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Rusted through! (PICS)
The cabinets were poorly installed and a hole underneath them allowed water from the wheel well to get under the rubber / foam mat.
Took the wire brush to the rust.
First layer of POR-15 black is now down!
Took the wire brush to the rust.
First layer of POR-15 black is now down!
Fleet Owner
Joined: Aug 2010
Posts: 21,255
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From: Reynoldsburg, Ohio
Also a big huge & large fan of POR-15---incredible stuff! 
When I did my '03 E250 complete floor I opted for the silver color---much, much more solid content. When used as directed by POR-15 to the letter its easy to apply and finished results better than expected.
I disagree slightly as to what caused most of that rust. Certainly holes in the floor left untreated contribute but the biggest culprit here was the OEM padded mat, front and rear. The padding absorbs moisture to the point it becomes saturated over time, never drying out. Because the floor is in constant contact with water rust forms inside, almost always unseen until significant damage has been done.
Holes in the floor aren't good naturally but if you've ever looked under a van during wet driving weather the underside of the floor is remarkably dry. Of course wheel well areas with holes get slinging water thrown against them the rust shown more towards the center probably wasn't caused by those holes.
Anyway good progress---just don't reuse the OEM mat and make sure your front seat area is also inspected and treated as needed. It suffers from the same disease.
Here's a link to my own odyssey: https://www.ford-trucks.com/forums/1...-por-15-a.html
When I did my '03 E250 complete floor I opted for the silver color---much, much more solid content. When used as directed by POR-15 to the letter its easy to apply and finished results better than expected.I disagree slightly as to what caused most of that rust. Certainly holes in the floor left untreated contribute but the biggest culprit here was the OEM padded mat, front and rear. The padding absorbs moisture to the point it becomes saturated over time, never drying out. Because the floor is in constant contact with water rust forms inside, almost always unseen until significant damage has been done.
Holes in the floor aren't good naturally but if you've ever looked under a van during wet driving weather the underside of the floor is remarkably dry. Of course wheel well areas with holes get slinging water thrown against them the rust shown more towards the center probably wasn't caused by those holes.
Anyway good progress---just don't reuse the OEM mat and make sure your front seat area is also inspected and treated as needed. It suffers from the same disease.
Here's a link to my own odyssey: https://www.ford-trucks.com/forums/1...-por-15-a.html
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Fleet Owner
Joined: Aug 2010
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From: Reynoldsburg, Ohio
Its a common thing where ever there are more than two seasons! 
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Tuned
Joined: Jul 2014
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Did you patch the holes? I live not to far from Rockville! This is some pretty good stuff too, and a bit cheaper. I like getting it in dark grey and then top coating it with Black rustoleum.
Paint Over Rust to Stop Rust Permanently With Chassis Saver Truck & Auto Underbody Coating
Paint Over Rust to Stop Rust Permanently With Chassis Saver Truck & Auto Underbody Coating
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