I spoke with a POR15 rep today. This is not going to be easy, but here's the outline of how this is going to get done:
- Interior floor pans and front fender aprons will be thoroughly washed down with aircraft stripper. This should remove any traces of paint.
- The aircraft stripper residue will be removed with many sponges and very hot water.
- What isn't removed will be sanded off.
- All areas of the car receiving rust-preventative paint will get a thorough washing of Marine Clean, to remove any grit, grime, oil, etc.
- Many more hours will be spent with a sponge and HOT water, washing off the Marine Clean.
- The Metal Ready* will be sprayed on the car to remove rust, etch the metal, and prepare for the POR15 paint.
- Once again, hours of wiping off the above with a sponge and hot water.
- Before the next step, I will apply some thick tape on the underside of the car, where pinholes exist.
- The best solution would be to remove the pans and weld in new ones. Unfortunately I do not have the experience to do this, nor do I have the tools. I could learn/pay someone, but I feel that the very minimal improvement made by putting in new pans would not offset the cost. The pans have been given several "tests" and they are very solid.
- Now that the metal is ready (get the pun?) the POR15 Rust Preventative Paint will be applied with foam brushes. The paint is self-leveling, so foam brushes should work fine.
- After one coat of POR15, I will put down a layer of POR15 Power Mesh on the floor pans with pinholes. This is a reinforcing fiberglass type material that will provide a little extra stiffness, and will seal the pinholes from the underside.
- 2 more coats of POR15 will be applied.
- Tape will be removed from the underside.
*Metal Ready has apparently been renamed to "Prep & Ready"