How much rust is tolerable - floorpan
 

Sorry guys, I don't have a photo, but on my 69 car there was some superficial rust that I sanded down to the good metal. But I can see very faint pock mark thingies that are very tiny. I don't want to get too perfectionist minded. My plan was to sand the whole floor pan to metal, por15 metal prep it, rinse it with water (that's what the bottle says to do), then por15 it with their semigloss formulation.

So where do you draw the line with rust? (after looking at his recent posts, I almost feel as if there is a little chris nielsen on my shoulder telling me to resect it.) :)

I really don't want ANY rust, but... it happens to even the very best of any steel bodied vehicle. The only thing you can do if find it and kill it! The amount of rust that you described seems to be a very minor amount and should be easily taken care of. It looks like you have a pretty solid plan of attack. Good luck!! Tony.

Interesting - that along with some a/c wiring improvements was my project for last week. No rust is good rust, but since you are dealing with minor surface rust you are catching it before it becomes a cancer. I agree that your plan of attack is a good one and there is really no good reason to cut and weld. I used the KBS coatings instead of the POR, but they are pretty similar.

One thing I would add to your plan is to get into the battery boxes. "As long as you're in there" you'll have most of the stuff out of the trunk and the wire wheel in hand. Since the battery boxes take a lot of abuse they are likely to be as bad - or worse - than the pan area. I cleaned mine out and gave them three coats of the KBS and feel much better until I get to the "real" trunk cleanup (tank out, wiring out, soda blast the area, KBS the whole thing and reassemble) which I can now delay for five years or so. Looks great, too.