What are some of the ways one can repair the rust that has eaten away the metal below the battery tray?? Is this a structural area, or more of a floor pan type of section where it is functional but not holding the car together??

My newest 123 has most of the metal below the battery tray missing. as in it was intact, until finger pressue showed it to be just the factory undercoating holding the metal flakes in place. the rust hole is large!! has any one ever repaired such a gap in their benz??

JD, i just did that area. i had a fist sized hole straight to the ground after i cleaned it up. what i did was as follows:

1) Took out little plastic piece (i don't know what it's for, but shaped like a kidney)
2) punched out the rust pieces and cleaned it up with snips best i could
3) took a wire brush and file to the area
4) cleaned with baking soda and water to "neutralize" acid (don't know if it works, but worth a shot)
5) vaccuumed and cleaned area
6) shaped a piece of 26 ga sheet metal with a screwdriver handle and cut it accordingly with tin snips
7) rust inhibitor on everything including new sheet metal
8) primed and painted new sheet metal
9) riveted new sheet metal in place

battery sits in there nicely even though i had resected 1/4 of the old battery tray. i also washed it in baking soda and water and coated it with rust inhibitor since i'm using it again. it actually looks pretty good and i'm definitely an amatuer.

I am trying to find a parts car that will donate the section I am missing... as the hole is almost 10 inches across... and it is a good opportunity to learn something...

JD, i just did that area. i had a fist sized hole straight to the ground after i cleaned it up. what i did was as follows:

1) Took out little plastic piece (i don't know what it's for, but shaped like a kidney)
2) punched out the rust pieces and cleaned it up with snips best i could
3) took a wire brush and file to the area
4) cleaned with baking soda and water to "neutralize" acid (don't know if it works, but worth a shot)
5) vaccuumed and cleaned area
6) shaped a piece of 26 ga sheet metal with a screwdriver handle and cut it accordingly with tin snips
7) rust inhibitor on everything including new sheet metal
8) primed and painted new sheet metal
9) riveted new sheet metal in place

battery sits in there nicely even though i had resected 1/4 of the old battery tray. i also washed it in baking soda and water and coated it with rust inhibitor since i'm using it again. it actually looks pretty good and i'm definitely an amatuer.


I also have rust problems under the battery tray. Just wondering if your fix is still holding.

Bob
1981 240D

I think anyone who is driving a W123 should check that area. I checked mine last summer, found a lot of dusty trash under the battery tray, then electrolite from the battery gets in there and eats right through the sheet metal. I found mine very rusty, cleaned it up with dishwasher soap and water, then washed it down with baking soda and painted it all up with black POR. Checked it this summer, looks like I did it yesterday.

What are some of the ways one can repair the rust that has eaten away the metal below the battery tray?? Is this a structural area, or more of a floor pan type of section where it is functional but not holding the car together??

My newest 123 has most of the metal below the battery tray missing. as in it was intact, until finger pressure showed it to be just the factory undercoating holding the metal flakes in place. the rust hole is large!! has any one ever repaired such a gap in their Benz??
Look through this thread for pictures of the repair.
Posts #175, #178, #179, #180, #181, #186, #188, #189, #190.

Who has the most rust and still drives
http://www.mercedesshop.com/shopforum/showthread.php?t=86054&page=1&pp=15

Some links you may want to read.

Body Mechanical & Trim + Body Sheet Metal:
http://www.mercedesshop.com/shopforum/showthread.php?t=142412

A new battery tray is available.
FastLane
Special Order Parts
1236200618

Item Number: 1236200618
Main Category: MB
Sub Category:
Description: BATTERY TRAY
Manufacturer: TYS:OES
List Price:
Your Price: $ 58.00
Core Price:
Weight: 3.130

http://catalog.mercedesshop.com/item.wws?qty=1&mfr=TYS%3AOES&sku=1236200618&price=58.00&cookieID=1YE1FF2PQ1ZK0Q9SDN