I got 2 holes rusted through my driver's side floorpan :(

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Follow up. What did you about that brake line that was nicked?
 

ghunt81

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I put some POR15 on the nicked part and left it alone. It really was not that deep and I'm not that worried about it for the time being. It looked worse than it was.
 

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Have you been able to seal all of the grommets/windshield/pinch welds?

I missed this one. I checked the pinch weld below the grommets, it looked pretty good but I put a little seam sealer in a couple spots that were possibly suspect. Grommets were all sealed with silicone. The windshield looks good, I don't think I have any leaks there.
 

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Once you're all done I recommend the last thing is to stuff some paper towels up front underneath the carpeting on both sides and take it thru a car wash. If they're dry when you get home then call it good. Then I'd look again each spring or winter/spring if you're really concerned about it.

So far mine have been fine but if I missed something I'll be pissed because I went over everything with a fine tooth comb....;d
 

ghunt81

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Got sound deadener down on the driver's side and most of the tunnel. Man that stuff takes forever to put in.
 

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Yep...it's a bitch but worth every bit of the effort. Post some pics...:karate:
 

ghunt81

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Front floor and tunnel are done. Still have a few small spots I will probably fill with some off the small odds & ends I have left over. I left some of the factory sound deadener in place because I really didn't feel like taking it all off. Probably going to go ahead and do under the rear seats as well since everything is apart.

5Zn9wCz.jpg
 

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Looks good. I'd also sound proof the rear vertical panels on each side of the rear seats as well. I found a significant amount of noise comes thru the side panels. While you're at it you might want to pull both seat belt tensioners and check down inside the panel walls for rust. I found a significant amount of rust under the plastic panels at the bottom of the well in each side which I had replaced with special UV plastic panels. Had them repaired twice previously which never really stopped the rust. Since replacing them w/UV panels have never had a problem since. Worth a look since you have everything out.
 

ghunt81

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Yeah I pulled the side trim pieces, I hadn't realized at first how easy they were to remove. Got some deadener on under the rear seat and behind the quarter panel on the driver's side but had to call it quits because it was just too late. Gonna work on it some more tomorrow evening and hopefully get the passenger side all done so I can start putting the interior back together, then comes the extensive cleaning for all the dust everywhere...ugh.
 

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Oh yeah, you can take the entire interior out of one of these in nothing flat if you know what you're doing. While you're on a sound deadener installation binge you might want to consider going into the trunk area as well. I kinda went nuts with it doing the entire interior/trunk; including inside the front wheel wells (on the front of both driver/passenger tubs to further cut tire/road noise. Maybe not needed but my car is now extremely quiet at all speeds where it wasn't before. The only area I really haven't touched is the roof. I'm probably taking a weight hit (likely added 30 lbs of the stuff in total) but okay in my book for the result I've achieved. It's a Lot quieter; stereo sounds better and much more enjoyable on longer trips. (Road noise drives me freak'in crazy).

Before you button it back up Highly recommend checking down inside the rear seat side panel walls on each side for rust (remove seat belt tensioners - only one bolt) since you've got it apart.
 

ghunt81

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I have enough to do the trunk, but it's full of interior parts right now so I'm not sure when it will get done...and yeah I'll look down in there. Sure hope there isn't more rust to deal with.
 

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Before you button it back up Highly recommend checking down inside the rear seat side panel walls on each side for rust (remove seat belt tensioners - only one bolt) since you've got it apart.

Well at least I got lucky for once. Pulled out those tensioners and looked it, and it's spotless inside there.

I have some sound insulating foam I'm going to put in a few spots on top of the sound dampener (since I had to pitch all the soaked factory stuff), then carpet is going back in! I may do the trunk sound deadener once I get all the interior parts out of it (my garage is too small, I had nowhere else to put all that stuff)
 

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Well I did the rear quarters and as much under the seats as I felt like doing (up to the edge of the trunk) and put down the sound foam (probably not needed but like I said, wanted something to replace the factory stuff I had to throw out). So I'm hoping tomorrow to get some time to work on it so I can vacuum the carpet and put it back in, and then start getting this interior back together.

gDrYqgX.jpg
 

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My, my, nice work... When you looked inside the walls did you pull the plastic covers at the bottom? They're glued down and take a bit of effort to pull them. If there is rust it will be under those panels. I was having issues with rust coming thru the paint on the rear quarters along the bottom on both sides. When I pulled the tensioners mine looked good inside as well until I pulled the plastic covers at the bottom of the well. Then it was a different story. Might not be needed in your case if you haven't had any rust issues with the rear quarters...just keep an eye on it. The only way I was able to stop it was having the lower quarters replaced with UV panels. They come in sheets and highly flexible until you hit it with UV light which makes rock hard immediately. Really cool stuff ;D
 

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Ahh I didn't know you had to look under the plastic covers. Well I guess I'll look but I haven't had much of a rust issue anywhere else on this car.
 

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Well I didn't take the plastic covers out but I looked up into the quarters from underneath through those holes in the bottom in front of the rear tires. No signs of rust anywhere up in there so I'm not too worried about it.

So right now I have the interior basically completely back together. Console is back in, seats are back in, so pretty much I have to clean the seats and dash and put sound deadener in the trunk and this thing will be ready to roll. Hoping it will be done by the end of the weekend!
 

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Good to hear.

Found some water on the driver's side carpet after a misty rain for two days. Was sure I completely sealed every grommet and other source for water intrusion into the cabin. Damn, I'll look at everything again. If I can't find anything I'm taking it to the dealer and let them figure it out. At least I don't have to worry about the floor now because it's completely fiberglassed at this point; no rust issues at least but this is frustrating and I really want figure out how the water is still getting in.
 

ghunt81

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Man I sure hope mine doesn't do that after all this work! At least there isn't any of that factory sound deadener under the carpet to just soak up the water now.
 

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Started on the trunk tonight. Good thing I never had a flat tire as I found out I had no lug wrench and no jack :nono: Also the spare was used enough that the tread is worn down and it was flat.

Trunk's gonna be weird, I didn't realize the area around the wheelwells was so oddly shaped. Also found a little rust down in the very bottom of the well behind the wheelwell on the driver's side (where the rubber plug is). Looks like just surface rust so I put a little rusty metal primer on it and will hit it with some paint.

Anyway I got the top flat part done down to the spare tire well, and part way down the sides where the channel is that the taillight wiring sits in. Going to be a lot of cutting and fitting for most of this it looks like. At least I can use big pieces for the spare tire well.
 

ghunt81

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Trunk is almost completely done. I'm not really sure where else in here I need to put sound deadener though. I still have a good bit extra left over. I did what you can see (whole floor) and the rounded part of the wheelwells. Does anyone put it on the rear trunk bulkhead? I did put a sheet on each side below the taillight mounting bolts because it was flat and almost the right size for a full sheet, but I wasn't sure about the rest.

AH0h7Rh.jpg
 

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