Rust Galore!!

[a-5 freak]

Lately, I've noticed a large amount of water in the passenger side floorboard of my ranger. So today I got off my butt and started investigating where the water was coming from. I've always noticed rust at the top of where the blower motor box, but have never thought much about it. When I poured water down the windshield, I felt water under the carpet. I ripped up the carpet and found that there was water coming from under the EEC-IV. I unbolted it from the side of the truck and to my horror, I found this.






Then I looked up the seam on the firewall and saw this.



This is where the the blower motor box connects to the firewall.







Sorry guys for the enormous size/ poor quality. I don't know how to re size images. Right behind the EEC-IV is a pretty good size rust hole about the size of a dollar. So Here's my question. What do I do? I have never dealt with rust before and I do not have a welder. Is there a way to fix this without a welder?

Thanks in advance!

 

[shane96ranger]

I'm not sure how crammed for space you are up there. You could always rivet some aluminum up there in lieu of welding some steel. I would POR-15 the hell out of it though with their 3 step process (marine clean, metal ready, then actual POR-15). I just used some on my Mustang and it is ROCK hard when it dries, and it resists water. Obviously you'll need to figure out why it got that bad in the first place. I see what I think to be a leaf? You may have yourself a bunch of crap in there acting like a sponge and keeping water in there for a long time.

Here's a link: http://www.por15.com/

 

[a-5 freak]

Ok thanks man!

 

[shane96ranger]

Ok thanks man!

By the way, POR in POR-15 stands for "paint on rust". You do not have to remove the rust, just paint over it after it's properly prepared. In fact, they recommend you leave the rust because it chemically bonds to it. There are videos on Youtube on how to do it. Sorry, it was late when I typed that, I meant to add it =).

Hell, here's a video on their site explaining what to do: http://www.por15.com/whatispor15.asp

 

[Jon581]

should he vacuum up the loose rust first?

 

[shane96ranger]

should he vacuum up the loose rust first?

Anything loose enough to be an issue should fall off when doing steps 1 and 2