How To Repair a Rusted Out Floor on a Ford Econoline Van and Prevent it from Rotting Out again
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- Опубликовано: 13 сен 2024
- As I removed the interior of my 1996 Ford E-350 Club Wagon, I was happy to find that the floor appeared in good shape with no significant rust. Unfortunately, I was saddened when I Removed the front carpet and found the floor was just starting to rot out in front of the driver's seat. On the bright side, it was not nearly as bad as it could have been when compared to other vans. Instead of getting upset and canceling my van build, I thought I would use this as an opportunity to increase my skills. I show How I was able to properly cut and clean out all the rusted-out areas. and make new patch panels to weld in. having to work with the body mount attachment for sure made this a bit more challenging. I also show how to coat all the exposed steel to prevent it from rusting further in the future. This project actually turned out better than I had expected even though I have very little experience with this sort of thing. I hope This video was helpful and inspires you to take on rust projects. Even if you have way more rust than I did fixing it can still be done but may take much more time and effort. It seems like this is a super common rust area on these vans but unclear exactly what the cause is. Thanks for watching!
Warning:
Welding can be dangerous, do this at your own risk. You are solely responsible for your own actions. Always use proper safety equipment for the job.
Disclaimer:
work on and modify a vehicle at your own risk. You are solely responsible for your actions. Always use proper safety equipment for the job.
Check out the Eastwood stuff I used below:
Eastwood MIG 90 Welder here: www.eastwood.c...
Eastwood XL View Auto Darkening Welding Helmet:
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The Eastwood Welder that I'll get someday in the future. Can do MIG TIG, stick, and flux core! The best welder you can get that runs on 120v only. Eastwood 140 Amp Elite MP140i Multi-Process Welder:
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Eastwood Rust Encapsulator Platinum: www.eastwood.c...
Eastwood Internal Frame Coating: www.eastwood.c...
Check out the video I made on the Eastwood MIG 90 Welder here: • The Best Value MIG Wel...
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Milwaukee 2485-22 M12 FUEL Lithium-Ion Right Angle Die Grinder Kit: amzn.to/3JtLcqo (paid link)
2in roloc disc master striping kit: amzn.to/3Lges5d (paid link)
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DEWALT 20V MAX* Angle Grinder Tool Kit, 4-1/2-Inch (cordless/expensive): amzn.to/3ZSMjFt (paid link)
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DEWALT DW4514B5 4-1/2-Inch by 1/4-Inch by 7/8-Inch Metal Grinding Wheels: amzn.to/3ZY5sWn (paid link)
Welding Blankets: amzn.to/3l2VX9L (paid link)
Spray MAX 3680001 1k Self Etch Weld-Thru Primer (Red Brown): amzn.to/3YwkGkB (paid link)
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Good job with the repair - very thorough. I saw you said it had been 8 months and no more leaks so that is good. Just as an FYI, I had the same area on my econoline rust out and I found the leak was coming through the grommet in the firewall that the wires were coming in through up in the back behind the pedals and the shroud. Additionally, I found a little crack in the seal of the firewall in that area behind the brake booster and the coolant reservoir. I didn't do anything fancy just a strip of eternabond tape on the outside and on the inside and one year later no leaks still.
hey thanks! yeah so far no water getting in even during some insane pour downs. good to know, your found where it was leaking from. need to drive during a down pour just to make sure there are no more leaks. always will check under the carpet from time to time
Did this whole thing back in 2021...Whole lot of freaking work in the exact same areas. Incredible Ford has not fixed this in 30 years...goob job!!
Nice, hows it holding up? Was it worse than mine? Yeah its crazy how all of them have rust here just about, the scary thing is both 2nd position body mount bolts have only 1/4 of the bolt left, but it was only the 2nd position bolts, my guess is water splashes up in between that thick bottom plate and the thin part and just sits. Also im not 100% sure where the water came from in the body mount divot. Im thinking the cracked windshield but it has now been replaced, water has never collected there after some crazy rain storms
Thanks!
@@4WheelKid the water comes from the top of the windshield. It rusts under the windshield seal and water comes in, then drips down the A pillars.
It’s holding up well, but we did a ton of work around the windshield, took it off, welded the rusted holes and a bunch of other fixes.
Ours was pretty similar to yours. I had to do both driver and passenger sides and also two big spots on the back, right above the rear axle.
You should be careful of the rear quarter panels, they fill up with water and rust. I caught it in time, but there’s holes they develop over time in the seam sealer right above the taillights, behind the doors. They let’s water drip into the quarter panels on both sides.
U have done stuff that I myself wouldn't tackle, to afraid I'd screw something up..u did an awesome job.like ur vids..keep it up my friend
helps, when you get the van for near free haha. I would be afraid to do it if at first on a $40,000 van haha. thanks!
Had similar condition on a 01 e350 7.3, rust through floor so bad I had to wear ear pro when driving…. My solution was cut out entire floor from another van (had a very open minded junk yard close), cleaned up rust, then laid right over old floor and spot welded, then painted. Worked great! Fun to see you tackle this!
oh I'm sure! so many of these vans get rust in this area. that's a good way to do it. should last for a good while. I recommend using a lanolin-based product on the underside. like wool wax, fluid film, or surface shield. spray it good and in all the cavities every year and the rust will be stopped in its tracks. I would just be afraid of moisture getting stuck in between the 2 floors and accelerating rust. Thanks!
Nice work Wes! Very meticulous and your attention to detail is impressive. I love following this build, but I really can't wait to see some video's with you taking it on tdub camping trips.
Thanks a bunch! hopefully, ill have all the mechanical, body work done by this fall, so can put the tw on the back and start doing some trips as I build the rest of the inside. will be doing a camping trip with the 4runner and the tw on the back in the next tdubskid video with the van update
Love getting to watch this build come together both here and your IG channel. Thanks for letting us come along for the ride.
Glad you enjoyed it, thanks for stopping by
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Cant wait to see you do camping and stealth camping videos in this.
Great job… that van will outlast me after your done with it
it will be great! hopefully I will have all the basic body/paint/mechanical work done by next fall so I can be driving it around with the TW200 on the back, already got the bed made inside. probably another year or 2 to completely finish the inside but that will be much more fun and I can use it as i'm building. also I did a 1 week stealth camp adventure in my 4runner with the TW on the back, ill put that vid on my tdub channel eventually
@@4WheelKid
Sooner the better on the stealth camp video with your TW
Looking great. Keep up the good work! Thanks for the video
Thanks, will do! No problem
Waaaaaay more than I woulda done, lol
but nice job young man 👍
yeah, I always go all out haha, thank you
It's going to be a brand new van
Haha close enough much cheaper than buying a brand new van, they are getting crazy expensive
I have to second this. He's knocking this out of the park. Attention to detail like no other.
I have a E250. All Econolines rust in tat spot. The water is not coming from the windshield or from underneath. It is a design flaw by ford. The plastic step cover sits on top of the rubber cab flooring allowing water from the drivers feet to run underneath and sit there and the padding underneath acts like a sponge. Nice fix!
Good to know, that makes sense, seemed like water had been sitting in there for a long time. Thanks! Should be good for a long time
Great job buddy👍
Thanks 👍
Water comes down the pillar posts on both sides of your windshield, its due to the seam below the gutter, of coarse the windshield, being glued it, it could be leaking too, you aren't seeing it now due to you resealed your gutters, so you may have sealed up your leak, I know, my 99 leaks there, and several have discussed the same issue with theirs.
interesting, that makes sense, cause I couldn't find the source even under intense rains. ill keep an eye out
Great video man
Thanks so much!
At first viewing, it seems like lots of work. But in review it was a lot of grinding and painting, with some cutting and welding. Not to under mind how cutting the plates and matching them to the van body wasn't time consuming.
Great job!
Yeah its not really too bad, mainly just cleaning out all the old rust. And making all the plates fit up well. Most of the time is in the prep work. Welding is the fun part haha. Also makes it easier that the rust wasn’t that bad yet. Thanks!
What would you do if yours was rotted out like the in the picture you included? Kine was kind of like that I've been cutting our and grinding down the rust as much as possible and treating it as well and covering the holes
I would head to the junk yard and cut out the parts I need at the junk yard from a van with less or no rust. might be hard to find out east though, but Colorado vans are not very rusty
someone said you can buy floor pans but I'm not sure where
Ótimo trabalho estou fazendo isso no meu econoline 1998
Thank you, best of luck, have fun
Hey Wes, did you go to school for this?
Hi, I did not. I went to school to be a mechanic but did not learn anything, body work/welding wise. learned that all on my own
This is nothing, I had to put new floor pans in the front of my 89 E150, the doghouse had nothing to seal to, huge hole at the engine, I fiberglassed the floor in the rear, was not as bad as the front, windshield was leaking really bad, previous owner screwed the trim around the glass breaking the seal and cracking it in several places. I put bedliner paint down on the floor and ordered a reproduction vinyl mat for up front, dropped heavy diamond plate aluminum in the middle of the van, have a bed built in the rear now, sure is loud inside, I should have put dynomat on the entire floor before I covered it to deaden the road noise.
Check your passenger rocker panel at the rear wheel, water spays in and rusts it, you may want to make a wheel well liner from a pond liner, buy it from Home Depot.
yeah not bad compared to some of the photos I have seen but they all start like this. so best to fix it now while it's easy to fix than wait till you can see the ground when you lift up the carpet. yeah, I'm using the sound deadening mat as well. got some in the front doors and it makes a huge difference when you knock on the door panel vs the other panels. for sure. my driver-side rocker panel at the rear wheel was rusting through. fixed that, turned out great, cut that panel out of the junkyard van and made a small patch, welded it in. video coming soon
@@4WheelKid My 99 has no rust in the floor, solid and white, but the top is leaking down the pillar, I just lack the ability to fix it and getting too old to fool with it.