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The rust starts at some holes cut in the floor at the factory, that weren't hit with the undercoating. Don't know why they were cut, and I'm too lazy to look it up in the other threads. I had floor rot on both sides. My co-worker's Altima only has one side with rot, while the other side is perfect since it doesn't have the hole.
The sound insulation traps water, and the carpet padding absorbs it. Rusting quicly accelerates
I cut out the damaged metal, and wirebrushed all the rust off. I brushed on two coats of rustoleum paint. Then I found two sheets of aluminum at Home Depot, cut them to fit under the car, and bolted them to the body with stainless bolts. I covered the aluminum with spray foam insulation before I bolted it up unerneath, and the foam spilled out of all the gaps. Finally, I hit it with a coat of undercoating. No welding involved, and the repairs probably cost less than $50. It's lasted me one Chicago-Salt-Covered-Road winter, and about to go into the next.
If left untreated, after two or three more salty winters, and I fear the structure of the car might have been compromised.
'05 Altima 2.5S, 129K.
Fixed: Rust holes in floor
Replaced: both CP sensors, Header without precat, alternator, blower motor resistor
Maintenance: Oil, trans fluid, brake pads & rotors, battery, serpentine belt.
I'm Never buying a Nissan ever again.
Last edited by Chuck80; 11-01-2012 at 01:32 AM.