Floor Pans- Rust prevention and Tunnel treatement, advice needed Options

[highways]

Hi all,

I'm working on my floor pans... I have them wire brushed down to bare metal. They are in overall decent shape though there is some rust around the perimeter where they meet the longitudinals. These corners seem innaccesable to all but a small wire brush (toothbrush size). Question is:

1. Should I apply POR 15 Surface Prep, then POR 15 to get in cracks, then Seam Sealer, then maybe another coat of POR 15 over Seam Sealer?

2. Or, should i just do Seam Sealer first over bare metal, partial rust areas around the perimeter? Then follow with POR 15?

Second question... the smaller 'cross tunnel'.. the one where the front seat adjustment bracket mounts, is in poor shape. Rust inside it looks bad... some of the lower edges are gone but it's still largely inaccesable to any tools or painting. I think my options are:

A. Drill some holes in top, blow it out, and spray as much paint in there as I can and call it a day.

B. Cut it out and weld in replacement. But is this part even available? And still how do you paint the bare metal inside after you've welded a new piece in?

Any advice would be appreciated.

[scotty b]

I do basically the same as Perry. Get ti to bare metal ( done ) next step is either coat it with OSPHO which is more readily available to the average consumer. Or give it a coat of etch primer then a coat of selaer. That is my normal routine. After that I use a spray undercoating form a gun, but a good quality spray can will get you good results. I am finishing up a complete floor install tody and had planned on posting some pics for you all of the normal pitfalls you run into. MY bnigets advise to all is to completely remove the under coating, and most importantly the tar boards inside. you never know what is really there until that crap is gone. For cavities, I have a spray wand I got from Strap On that allows me to shoot Ospho into the longs, I let it sit overnight, run water through to clean and neutralize any remnants, let that dry and then coat over it with Eastwoods rust encapsuletor.A teaser pic