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RoadForce

Member Since: 17 Jul 2014
Location: Holland
Posts: 337

2000 Defender 130 Td5 HCPU Coniston Green

Footwell repair question

Hi, I am currently doing up my rotted footwells and have ordered some of the usual repair sections to make my life easier, however I see that the footwells in the car are "double skinned" with the outer skin having some sort of corrugations in it, whereas the repair panels are a single skin. Part of the outer, corrugated skin has also rotted away but there is no repair panel for that, so I will just have to cut it back to good metal and then what? What would be the best way to deal with this? Leaving a gap between the two skins will be a massive moisture trap. Seam seal it up as best as I can reach, or is there a better way? Defender 130 HCPU Td5 MY2000

5th Aug 2016 3:52pm

RoadForce

Member Since: 17 Jul 2014
Location: Holland
Posts: 337

No one? Defender 130 HCPU Td5 MY2000

7th Aug 2016 10:11am

Iggle piggle

Member Since: 10 Sep 2014
Location: Wales
Posts: 378

1989 Defender 90 V8 Petrol ST Alpine White

Only tackled the drivers side & it was only the outer skin that was rotten on mine, inner was ok
We just drilled all the spot welds and unpicked the two skins, cleaned the inner up, a few coats of zinc paint & stitched the new to the back of it through the spot weld holes & plenty of seam sealer to finish off

7th Aug 2016 7:36pm

Iggle piggle

Member Since: 10 Sep 2014
Location: Wales
Posts: 378

Click image to enlarge

7th Aug 2016 7:37pm

RoadForce

Member Since: 17 Jul 2014
Location: Holland
Posts: 337

Thanks for that, looks like a good job. my situation is a bit different so if anyone has some ideas, I'd love to hear them! Defender 130 HCPU Td5 MY2000

9th Aug 2016 7:21pm

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Cut out the panel your replacing then take the outer panel back to good metal and weld in a plate (it shouldn't need to be corrugated if you can't find a replacement panel) then grind off all the paint from the inside of the outer panel before welding your new replacement panel in and paint it with por15. Paint the back of the inner replacement panel (except for where you need to weld) with por15. Weld on the inner panel and drill a small hole (unless there is already a hole in it) and spray loads of wax in the cavity then paint inside and outside as usual and stick a bung in the small hole you drilled. Ray
My build thread
http://www.defender2.net/forum/topic17615.html

9th Aug 2016 7:43pm

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