My wife's smooth roof 850 panel van has had new floor panels welded in over the original floor which has some rust - not that much but enough to warrant the original repair.

The new panels are properly welded with weld right around the seams and are not now rusting. Sills seem fine.

What is the current registration requirements ?? is this a legal repair ??? The van has not been registered for many years.

I dont really want to cut out a functional floor (as well as the original rust floor) if I dont have to.

Comment please

Mike

are the new ones on the inside or the outside?

If on the inside and covered with carpet, rego inspector will look at the outside rusty floor and ping you i reckon.

Even if not rusty now, they will eventually be a problem because the original rusty metal is still there.

I would plan on redoing it all myself, because I would just be able to hear the rust forming the way it is now.

cheers
michael

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The new ones are on the inside but it no big deal to lift the carpets for an inspector.

There have several recent changes in what is required for rust repair of floors and that is the information I am specifically after.

Its easy enough to cut away the old floor and deal with rust correction and subsequent conversion and prevention. Its a lot harder to take out two floors (and more costly) if its not required and they are structurally sound.

Mike

IMO that is a "dodgy" rust repair because the rust is still their. If you want to get through roadworthy repair it properly by completely cutting out the old rusty bits and replace them with perfect new/replacement panels.
The inspector will simply look under the car, see the rust and tell you to get it fixed properly (because pits might fall off and become a danger to others).
To do it "dodgy" simply whack the replacement panels on the out side so the rust can't be seen and hope like hell the inspector doesn't look under the carpets But the rust will still be their and your rare smooth roof van will continue to rust away which would be a big shame for everyone.
Please please please repair it properly, it will be stronger, safer and will make the car last longer.

P.S. I'm not trying to have a go at you this is just my opinion.

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Sadly I agree with the comments regarding leaving the original rusty panels in place.
Eventually the rust will comne back. The only way to repair rusty panels is to cut out all of the rust and replace with new steel.

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1969 Cooper "S"
1967 Mini Deluxe
1973 Clubman Van (the fleet spare)
1978 ex 1275 LS ("Wizard" Eaton Supercharged)
2015 HSV GenF GTS(occasional drive & tow car)
2019 MINI F55 Cooper S

Agreed. If anything, leaving old rusty material there will just accelerate the rust problem. Lots of water and dirt traps to help the cancer continue to spread.

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1967 Cooper S - new front bearings to do.
1965 Cooper S shell - Slow progress. No time or money!
1966 Deluxe- next rustoration!
Mk 2 & XJ6 Jags. Less said the better.

If the rusty part is still there and the new one is on top the new one can not be in the place where it should be and also make it look like such a horrible job. I might still be plenty strong enough as it has double panel. but yuk!

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Mike put some pics up so we can see exactly what you are dealing with.

Will do in the next few days when it goes up on the jack stands and the subbies are out - may even get to put it on its side on tyres to get a better look especially if its going to need a lot of angle grinding.

Mike

I also agree with the other comments ,leaving the old rusty panel there is bad news.

I would think that not only will it continue to rust away but it will do this faster due to the water/dirt trapping ability of the double panel. This will ultimately meean that not only will the old panel continue to rust but so too will the new panel and you will have to fix it properly anyway.

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1964 998cc Cooper
1971 Mini K x 2
1972 Clubman GT