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rustyredwreck

Member Since: 16 Jan 2020
Location: Oxfordshire
Posts: 24

Footwells - Not Sure Which Way to Go - Any Suggestions

Click image to enlarge
Morning all,

I have a 2003 90 CSW. Last weekend I removed all of the matting in the front to see what state the footwells are in (see pictures). I don't have a garage big enough for the 90 and am limited to working on the car on the front drive.

I am planning to "sort" the footwells out and have (I think) two options:
(i) wire brush/ sand down and treat with a rust retardant and paint over - and then put the mats back and forget about it for 12 months or
(ii) somehow remove all screws from the floor panel, replace the floor panel seals, treat both sides of the floor panels and then paint and replace with new screws etc. and then put the mats back.

Option (i) is quicker - I have to fit the work in between spells of inclement weather and the cold but (in my mind) not as effective

Option (ii) - is a better, long term solution but I know it will be a tricky job getting the screws out (I am not very gentle with angle grinders) and will take longer.

I would appreciate anyone's thoughts, suggestions or horror stories.

Click image to enlarge

5th Nov 2020 9:25am

Scotm

Member Since: 28 Feb 2014
Location: Aberdeenshire
Posts: 666

2012 Defender 110 Puma 2.2 SW Orkney Grey

I would go for second option then it is done properly but as you say doing it this time of year is problematic, so maybe just treat the rust the best you can now and sort properly in the spring?

I think most of the screws are into plastic clips so might come out easier than you think. Drilling the heads off might be better than an angle grinder.

5th Nov 2020 9:55am

donmacn

Member Since: 06 Nov 2017
Location: Nth Scotland
Posts: 1845

I'm with Scotm - better to do it properly, but at this time of year maybe something quick.

One thing I would say is to try and get those screws out, rather than skimming the heads off. That will allow you to lift the floor, but then you'll also have to deal with the remnants of the plastic inserts - and those ones are stronger than you think.

Maybe one of the 'mangled nut extractor' things in a small size would grip the screw head? Or a left hand drill bit followed by a stud extractor if needed?

.......Or you could just grind them off too once you have the floor up.

Either way, I'd suggest having a new set of those inserts to hand, and when I did mine, I used stainless screws on the replacement, with a nylon washer to separate the screw from the alu. floor. Donald

1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong
(The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html )
2000 Range Rover P38 4.0L V8

in the past..
RR classic - fitted with 200Tdi
1984 RR classic - V8 with ZF auto box
1993 Discovery 300Tdi

not to mention the minis and the Type 2 VW camper...

5th Nov 2020 10:04am

X4SKP

Member Since: 29 Nov 2013
Location: Berkshire
Posts: 2295

2010 Defender 90 Puma 2.4 SW Stornoway Grey

Hello rustyredwreck

Or Option 3
As you are where you are... remove all loose rust... paint with a good Rust Converter,
if you have the same underneath then do the same, Replace Mats, wait until next
Spring then Option 2... if Rust is mainly inside and minimal / not outside, find and fix leak(s)

Option 4
Leave as is but repaint Red (sorry couldn't resist)

Good Luck

SKIP
https://www.defender2.net/forum/topic83242.html

5th Nov 2020 11:45am

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5850

1999 Defender 110 Td5 SW Caledonian Blue

Option 5. Buy a 2nd hand set of floor panels. Paint etc and leave to dry and then fit.? 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

5th Nov 2020 11:46am

rustyredwreck

Member Since: 16 Jan 2020
Location: Oxfordshire
Posts: 24

Thanks everyone for your suggestions.

I really want to do the job just once and do it properly, so maybe there's another option - don't do anything until Spring?

I'll have a think.

X4SKP - you're closer to the truth than you know. Rusty Red Wreck was my first land rover - a fantastic Series III 109 CSW in Masai Red - which I absolutely loved. I read all the "buying a series III" articles I could find and, armed with a hammer (to gently test the chassis), went and inspected it, bought it and drove it 200 miles home. Love at first sight! Next day put it on a ramp and I have no idea how it happened but I missed every bad bit of chassis the day before - it was a wreck. I still miss that 109.....a Defender just isn't the same. One day I'll get another series III 109 CSW - Rusty ended up in the states i think.

Thanks again all.

5th Nov 2020 12:29pm

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