floor pan rust - Nissan Forums : Nissan Forum
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#1 Old 09-04-2011, 10:50 PM
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floor pan rust

So I'm sure most are familiar with the floor pan rusting situation on 02-06 Altimas. I've just discovered a rust spot about 1' X 5" on my passanger side, and minor rusting on my driver side... I've seen alot of scattered info about this problem but I'm hoping to condense it into one thread. To make this problem known.
I am a 17 year old who bought a 2005 Altima 2.5 S (16 at the time) I've had the car for roughly 4 months. OBVIOUSLY this is an excessive amount of rust for this year of vehicle. With or without salt.

I find it disguisting not only that Nissan refuses to pay for their mistake but also that I was promised a GREAT all around inspection by the car dealer. There is NO WAY that if they did an even less than par "inspection" they wouldn't have seen this. So I am thinking either I was lied to and there was no inspection, or I was lied to and wasn't told about this costly problem.

Although it is not acceptable to put this burdon upon anyone I find it especially hard to believe it would be done to a hard working 16 year old who is making the payments on his own.

If you could help me out I would like to get many more stories and pictures before I bring this up to the dealership so I have some support.. I plan on contacting the dealer, giving them bad press. If I fail I will contact Nissan directly. If that fails also I will sell this car (while telling the next owner about this problem) and buy a make of car other than Nissan.

I'm really hoping to get some good information to help me resolve this issue, Thanks alot in advance.

P.S Sorry about the extremely long thread. I really needed to vent about this issue.
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#2 Old 09-05-2011, 02:10 AM
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theres tons of info in here, just use the search option...

http://www.nissanclub.com/forums/200...rust-hole.html

Altima Rust Shocker! - Nissan Forums: Nissan Forum

http://www.nissanclub.com/forums/200...-your-car.html

http://www.nissanclub.com/forums/200...rust-hole.html

http://www.nissanclub.com/forums/gen...by-cancer.html

http://www.nissanclub.com/forums/200...-got-rust.html

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#3 Old 09-05-2011, 03:05 AM
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If all else fails, I have a cheap fix to the problem. It will cost like $50 and about 5-6 hours of your time. Its the link in my sig
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#4 Old 09-05-2011, 11:51 AM
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These cars are made from garbage metal

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#5 Old 09-05-2011, 11:46 PM
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i just fixed mine but larger do it now

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#6 Old 09-06-2011, 12:17 AM
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welding galvanized metal???

Quote:
Originally Posted by SzczDavi View Post
If all else fails, I have a cheap fix to the problem. It will cost like $50 and about 5-6 hours of your time. Its the link in my sig
I take it you don't weld much... The zinc fumes are very toxic!!. Don't weld galvanized metal. Use sheet metal only.

BTW other then your choice of metal, the write up is very good.

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Last edited by peelman; 09-06-2011 at 12:23 AM.
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#7 Old 09-16-2011, 03:31 PM
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After working on my floor pan I've come to the conclusion that the hole was supposed to be plugged from the factory and that's what is causing the rust. I wish I could go back 8 years to when I bought it and plug those 2 holes.

I actually couldn't see anything except rust stains until I got my wire brush going, then I found a mess underneath. I filled that hole in with bondo and then did primer and 2 coats of herculiner.
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#8 Old 09-17-2011, 02:45 PM
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Quote:
Originally Posted by peelman View Post
I take it you don't weld much... The zinc fumes are very toxic!!. Don't weld galvanized metal. Use sheet metal only.

BTW other then your choice of metal, the write up is very good.
I didnt have the proper equiptment to weld so I just used the short stand bondo for the edges, but thanks for the info, ill add that in the how to
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#9 Old 09-17-2011, 03:21 PM
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Good stuff

Galvanized sheet metal can be used if riveted in place too, then covered over with fiberglass...

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#10 Old 10-30-2012, 07:42 PM
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2002 Altima 2.5 S Rusted Floor Pan Repair

The crook who sold me this car had placed sheets of heavy gauge metal INSIDE the car to make the floor feel solid, but did nothing to repair the damage from the outside, so there were still large gaps where water was getting in and soaking the carpet.

After cleaning up the rust and cutting away weakened metal, I had holes on both the driver and passenger sides that were about 12" x 5". I coated the area with rust converter, then riveted in galvanized sheet metal from the outside. I put rivets every inch or so around the perimeter of the patch. Next, I used a high quality acrylic exterior caulk to "seal" the edges of the patch and the rivets, and finished with a few coats of rubberized undercoating.

Hopefully, this will last a couple of years...
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#11 Old 11-01-2012, 12:29 AM
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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.

Chuckie
'05 Altima 2.5S, 119K.
Fixed: Rust holes in floor
Replaced: CP sensor, Header without precat, alternator
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 12:32 AM.
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#12 Old 11-01-2012, 12:22 PM
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Quote:
Originally Posted by Chuck80 View Post
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.
This is the only part of this statement that is true. I'm almost amazed at what people say regarding this.

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#13 Old 11-01-2012, 01:59 PM
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Quote:
Originally Posted by SERendipitous View Post
This is the only part of this statement that is true. I'm almost amazed at what people say regarding this.
Correction: I'm too lazy to go back through all those threads again. I did go through them over a year ago to research why this happens, how some were trying to get Nissan to fix the problem, and and how others were fixing it themselves. In fact I also used other Nissan forums as well, not just nissanclub.com, and I remember seeing some postings about the holes in the floor theory. A theory that is further strengthened by the pictures I posted of my car, and by what I've seen on my co-workers car.

If something else has been discovered in the past year, or if I missed something, I would love to know about it. So, you called me out, what exactly did I get wrong?

Chuckie
'05 Altima 2.5S, 119K.
Fixed: Rust holes in floor
Replaced: CP sensor, Header without precat, alternator
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 02:21 PM.
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#14 Old 11-01-2012, 02:50 PM
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The holes weren't cut (they served a purpose on the assembly line), they were all under coated, and if your coworker didn't have a hole on one side of the car (theres one in each floorboard, front and back) it's because it was already repaired. This is a problem for all 3rd gen Altimas, 6th gen Maximas, and probably other Nissans with the same flaw. Yes the problem is the hole but more specifically when the under coating cracks around it because its allowed to flex. A great habit to get into is to recoat the areas periodically to make sure it stays sealed so water can't get in.

The fact that you're on other forums is irrelevant. Some asshat on the ORG actually called them drain holes, said that they need to be there, and that you shouldn't seal them. Rumors must be squashed before they gain traction and infect others.

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Last edited by SERendipitous; 11-01-2012 at 02:52 PM.
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#15 Old 11-01-2012, 11:46 PM
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Quote:
Originally Posted by SERendipitous View Post
The holes weren't cut
Wrong.

And I don't buy the "under coating cracks around it because its allowed to flex" around one tiny hole theory. Undercoating is flexible.

Chuckie
'05 Altima 2.5S, 119K.
Fixed: Rust holes in floor
Replaced: CP sensor, Header without precat, alternator
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 11:59 PM.
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