Trunk Pan

I pulled up the fake Dynamat in the trunk pan to discover (I wasn't really surprised) a large amount of rust on the pan in the trunk, mostly under where the battery obviously had sat. As usual the previous restorer had done a top notch job and not only made the battery's spot the only place with Dynamat he had also obviously not had a battery box and fumes and probably some acid leakage had eaten into the metal.

So I went to scrape the large amounts of rust with the paint scraper when I got to that section under the battery I came into a much more serious problem than surface rust. In several place throughout a 5 ' wide by 1' long section of pan the rust had eaten all the way through, where it hadn't eaten clean through it had thinned to the metal to nearly paper thin. I think right now my plan of action is to cut out this section, fabricate a new one, and weld it in.

Looks just dirty with Dynamatting...

That's not dirt. Well some of it is

Holey-pain-in-my-ass Batman!

Frame Rust

The floor pans of the Sonett were covered with knock-off Dynamat, I could see in the cracks in the previous owners half-assed insulation/rust prevention attempt and in those cracks was rust. So with a flat head screwdriver and a paint scraper I scraped out all the old Dynamat, popped out the drain plugs in the pan and vacuumed up all the stuff that was stuck under the matting.

As you can see the floor pan was absolutely covered in surface rust, thankfully a good solid tap showed me that the pan was still solid. So I set out to remove as much rust as I could, combination of a wire-wheel, hand sander, and belt sander; both with about 200 grit sandpaper. Then I vacuumed up the rust and dirt that came up, wiped down the area and resprayed it with my probably 250th bottle of Krylon black anti-rust enamel. Now I can sit on the floor pan and not feel like I immediately need a shower, plus it should stop the rust from getting any worse and keep the floor solid.

Before:

After some preliminary wire-brushing, sanding:

After a little more thorough treatment:

After Paint: