Recently I came across a metal restoration product called Por-15 that is simply amazing. It is very easy to use and does an incredible job in protecting floorpans and other rusty areas while virtually guaranteeing that the rust will never return. See below (left=before, right=after).

Here is how it works: Rust is caused by moisture coming in contact with metal, which causes a chemical reaction called oxidation. Paints protect, but are softened by age and moisture. Por-15 is strengthened by moisture, It bonds to the rusted metal and forms a rock hard, nonporous coating that won't crack, chip or peel. It keeps moisture away from metal with a coating that becomes stronger when exposed to moisture. Rusted surfaces are best; seasoned metal and sandblasted surfaces are also good. I bought the Floorpan/Trunk restoration kit which included everything needed to restore the pan and cost $132 including shipping. Try replacing a pan for that price! Follow the application guide below and you too will be amazed with the results.

How to apply Por-15:

Step #1. Remove rust and scale: Wire brush loose rust and scale. Vacuum out area of any debris.

Step #2.Clean: prep surface with Engine/Marine Clean, this alkaline cleaner removes grease, oil, mildew, soap and wax and insures proper adhesion. Rinse with water and let dry.

Step #3. Etch: apply Metal Ready to neutralize rust and etch any clean bare metal. This allows better adhesion of Por-15. Keep wet for 20-30 minutes. Wash with off thoroughly with water. Allow to dry.

Step #4. Coat: Brush or spray on Por-15. It is as strong as powder coating yet remains flexible and resists chipping. Fill in large holes with Steel Reinforcing Fabric. Fill in small holes and smooth out rough surfaces with Por-15 Epoxy putty. Allow to dry.

Step #5. Top Coat: Brush or spray on Chassiscoat Black Por-15. This provides chemical bond to form a durable coating to stop rust. Allow to dry. The surface can be painted if desired.

They have additional high-temp coating, fuel tank, stripper, degreaser, primer and other repair kits in their catalog. Por-15 has a web site at www.por15.com or you can phone them for their nearest retailer at 1 800-457-6715 (fax 1-973-887-8007).