How can I fix this?

[A930Rocket]

At some point, the plywood floorboard on the driver side of my 911 got wet or brake fluid dripped on it, and it’s damaged at the bottom left corner.

Looking online, I see new floor boards for $400 for Porsche and less for ABS or aluminum, which I don’t want. Design911 in the UK has one for $145, including tax and shipping, plus any shipping taxes/tariffs/etc.

So, how can I fix what I have?

I was thinking I could squeeze glue into the loose plywood sheets, clamp it up, to firm it up.

Then splice in a small section, but the finished plywood I can source is 1/4” ($17) which I could sand down. And then, sandwich it with a veneer ($20). Total $37 and time. Tools are not a problem.

Yes, I could buy something, but I like doing this kind of work.

Ideas?

[rwest]

What about fiberglass cloth and resin. A few layers and let it dry?

[Steve Carlton]

Dude. $145...

[A930Rocket]

Originally Posted by rwest

What about fiberglass cloth and resin. A few layers and let it dry?

I’ve never worked with fiberglass, but that could be an option.

As a builder, I work with wood all day, so that’s my go to method

Originally Posted by Steve Carlton

Dude. $145...

Hahaha!

[rwest]

Fiberglass is pretty easy, you cut the cloth to size or a bit over, mix the resin and hardener and brush it on. You can sand and grind as needed.

[rcooled]

Originally Posted by rwest

What about fiberglass cloth and resin.

Yes, and make a new metal hold-down bracket that fastens further up into solid wood.

Or, you could just cut the damaged section off and fashion a replacement in the same shape. Make a new larger hold-down plate that also serves to join the replacement piece to the undamaged section.

↓ Not quite what you're dealing with, but a similar concept...

[Tobra]

You guys are as bad as me

+1 for the fiberglass

[flipper35]

Minwax makes a resin that soaks in and hardens, then you could FG over it.

[A930Rocket]

Good ideas, guys. I may tinker with it over the next couple of days and then decide if I want to buy the Design911 part. There’s no rush.

[john70t]

The beatings...i mean rust..will continue until morale improves.

It looks like metal+wood. Non-structural. Covered by carpet.
How much time do you want to spend.

[rockfan4]

I'd make a new, larger mounting bracket. Use the existing rivet hole on the right and make two new holes higher up in good wood to mount it. I wouldn't even fix the wood unless this is some over the top restoration project.

[LWJ]

Epoxy can make space ships.

Trust me. You can glue up virtually anything with two part epoxy.

[Zeke]

Router bit with ball bearing guide on bendable plywood. Steam bend it. Make a bunch and sell them for 75.

Other than that, a small epoxy kit from HD will do you just fine. Clamp up with cauls covered with packing tape. Both surfaces will be perfect. Trim the edge and Bob's your uncle.

[KFC911]

GoFundMe .... I'll donate a little .... very little

Only $144 left .... help him out boyz!

[oldE]

Or you could do what I did: Cut back to the area with no delamination, you should still be in the area where it is flat. Scarf join the piece to replace what was cut out.(You get to use epoxy for this). Cut the new piece to shape (you remembered to make a pattern, didn't you). Sand, paint, clean up the metal piece and reattach.
I just realized that was 25 years ago.