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Old 07-09-2008, 02:47 PM   #1
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cargo door leak floor repair

The floor repair is finally finished. 2 weeks to chisel out and dry everything so water wasn’t present when I treated and reinstalled everything.

Tearing out the floor OSB, the insulation was saturated with water.

Stripped down cargo compartment.

After cutting out the floor well past the water-damaged area, I matched the dimensions of the missing floor with new OSB. I was careful to set the depth of the cut so I didn’t hit the floor joist. I put 3 heavy coats of polyurethane on the new floor insert, the overlapping existing floor, and all the framing.

I scabbed in a 14” cross support with glue, 3” screws and a ‘T’ lag bolt so screws from the front through the rock guard have an anchor to the frame. Leveled with wood filler.

Styrofoam insulation cut to fit to replace the fiberglass in the floor and along the front slope.

After screwing down the cut of poly’d OSB, I glued and tacked down 2 side by side19”x36” cuts of wains coating to provide a mating surface for the spray glue and linoleum. I cut an additional piece for the slope to cover the removed patch of damaged paneling.

A wooden rail was added inside the opening so that gear wouldn’t slide and bang the door. Per suggestion from the board here, the extreme rubber weather sealant got cut and taped in all the way around the inside closing contact points. A new door catch with a working spring was also installed.

Finished cargo area.

Thanks for looking.

Take care,

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Old 07-09-2008, 04:53 PM   #2
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Looks great Jason. You did a very nice job


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Old 07-09-2008, 09:59 PM   #3
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The first pic's looks real ugly

The last pic looks real nice

Great job and thanks for sharing.

You are handy I can tell.

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Old 07-12-2008, 10:51 AM   #4
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excellent - is all i can think of - great job!
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