Dealing with Battery Tray Rust

[exoticdvm]

Have a fairly rust-free '78 Bus (campmobile). However, I suspected some rust issues affecting the battery trays. After removing both batteries, there was definitely rust present including a small eroded hole under the auxiliary battery. Was planning on a POR-15 treatment, but not sure if this type of rust damage warrants welding in of new metal. How would you treat this? Go forward with POR-15? More serious intervention? Any advice appreciated! Photo attached.

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1978 VW Westfalia
http://www.marcandeliana.com

[pioneer1]

That's a perfect place for POR15. Be sure to do the proper prep work. They also make a mesh I believe that will handle that rust hole. Put a bolt in the bracket hole so you don;t fill the threads with the POR. Do the underside as well. This message depends solely on how thick the remaining metal is-you know a battery is pretty heavy
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"Always waiting for tomorrow ruined everything"

'85 Porsche 911 Targa

'76 Westfalia project

[Poptopcamper]

I have a 78 and one of my trays was totally rotted. The PO put a piece of carpet in that hole, to hold the battery. The other side was a little bit worse than yours, but solid. I POR-15ed both sides. I bought new trays from BD, but I'm not ready to weld yet. Yours looks like POR-15 will give you some more miles. As long as it's still solid enough to support the battery.
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If you only have one tool in your tool box, and it's a hammer, pretty soon, everything looks like it needs to be whacked!
1978 VW Riviera
2021 Dodge Ram 3/4 ton
2020 VW Tiguan
2001 Harley Electraglide Classic
1986 BMW R 800cc motorcycle
2002 Chevy Camaro Z28
1999 Harley Sportster 1200 Custom

[Wildthings]

Treat the rust with some form of phosphoric acid (like POR 15) and then put several layers of fiberglass on the bottom of the box and run the glass up the sides to the height of the battery or a bit more.

[popuppopdog]

[Wildthings]

[BUSBOSS]

If you go the POR15 route, follow the directions with attention to detail and make sure to clean and treat the underside also(wheel well area).

I prefer the cut and replace method with regards to battery trays.
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All the redemption I can offer, girl, is beneath this dirty hood
1976 Westfalia
1970 Karmann Ghia Convertible (sold - but not forgotten)

[Wasted youth]

Your tray will eventually look like my 1977's tray:

But the 1970 bus I had was Swiss Cheese, yet solid around the edges. I decided to cut out portions of the holes, weld in sheet metal patches, then douche it with POR-15:

[OB Bus]

I don't weld.
After treating the remaining metal with POR15 (or equivalent) I repaired my battery tray with a piece of 3/4" exterior plywood 11 years ago. Still there and it is fine.
That being said someone on this from (Gary/Aeromech?) got a new metal battery tray and used panel adhesive to "glue" it into place. Looked very clean. If I were to do another tray I'd go that route.
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Larry in OB
Stop dead photo links! Post your photos to The Samba Gallery!
69 Westfalia and 2002 Eurovan Camper.

[Spike0180]