After tearing down the inside of the cargo area and cleaning it up, it was time to remove the small amount of rust that had formed inside the van’s cargo floor. After a quick run to Home Depot to pick up some metal brush bits and 3m dust masks, I began to chip away at the rust with a drill bit. It was a slow process, and at first I used a portable drill, but quickly ran out of battery. Modern rust proofing paint applications make it possible to apply it over the affected areas without removing the rust, but as Gaia will be a home for an extended period of time, I wanted to remove all the corrosion that had developed inside the cargo floor and then apply the rust preventative paint. Using a corded drill, it wasn’t until late into the evening that I got to a point where I was happy with the result.
The cleanup process also exposed the areas where drywall screws held the factory wooden floor in place. It didn’t take long to remove the screws and clean them up. I mixed together some JB weld and applied it over all the little holes, mostly located in the back of the cargo floor, and let it cure overnight. The next morning I cleaned the entire cargo floor and the bottom of the side walls with acetone, and then with a POR 15 degreaser. Painter’s tape was applied to the side walls and to the bolt holes in the floor.
The floor was finally ready for a rust proof paint application. Having done a bit of research beforehand, I opted to use a can of POR-15 Rust Preventative Coating. A quart was more than enough to cover the entire cargo floor and wheel wells of a 144″ Sprinter van, and there was still plenty left for a second application. I used a 1.5″ wide nylon brush to be able to get into the smallest floor ridges, and painted the entire floor with it. The paint is thin and spreads very easily, making it a breeze to apply. It does take a bit of time to get through the whole floor, and I had to apply a second coat as the paint had trouble sticking in some areas of the floor. After the second coat dried, the van was ready for a brand new floor installation. A bit of a warning to those attempting to do any POR-15 rust preventative coatings – make sure you are covered head to toe in clothing and wear proper gloves, as the paint does not come off for weeks if it dries on your skin, and don’t forget your eye protection. If you do end up painting any areas of your vehicle with POR-15, please share any additional input you may have in the comments section!