Help...rust!!!

[VanMama]

I just bought a 1999 Dodge Ram van 3500. It was recently inspected, new brakes and components (calipers etc), new alternator, new battery, and engine runs great. However, after removing interior (cloth ceiling, plastic trim, rubber/carpet floor coverings), I have found 3 concerning rust holes in the floor - large ones (fist sized or bigger). I will take pictures when I'm able, but my main concern is that my children and I will be traveling/living in this van for a year (maybe more) and I need it to be safe and able to bear the weight on the flooring of our beds, porta potty, and other stuff. We live in the northeast which is why it is so rusty (salt on roads 6 months out of the year), but we will be travelling to drier places and like I said - just for a year. After that I may be able to upgrade to an RV or we may decide to settle in the southwest. The body isn't bad at all and it did pass inspection, so I know it is "safe" in that regard. My concern is I plan to insulate and add laminate flooring. Would covering with truck bed liner paint on outside and using plywood on inside before insulating (and laminate after) be enough to hold up?? Or am I screwed and need to scrap the vehicle, take the hit to my $, and just move to the SW without living in this van for a year?

 

[GotSmart]

You are planning on this being a temperary vehicle, so clean it up with sandpaper, and use JB Weld to cover the holes with galvanized metal.  You can buy that at hardware stores.  Paint it with Rustolium, and go ahead with your conversion.

 

[Weight]

Brake lines also rust. Common problem in the NE. Have them inspected. As far as the floor, seal the holes as best you can and use a sheet of plywood to spread the load on the floor.

 

[gapper2]

First do what G0tsmart said.

Second do what Weight said. 

Third get Carbon Monoxide detector and learn how to read it.

Then you and the chillens live and recover from your loss.  My prayers are with you and yours.

 

[highdesertranger]

if you have holes in the floor the size of a fist I would be worried about the front frame horns and brake lines. have you checked those? I would ASAP. I can't believe it passed inspection with holes in the floor. I wouldn't trust the inspection. highdesertranger

 

[Snikwahjm]

One time we had all our vehicle down for repairs and I borrowed my husband's buddy's old Chevy truck to go to somewhere. It had fist sized holes like that in the floor and bed and since he was a contractor stuff fell out all the time. The back fenders were held on by bunge cords and the drivers door was wired shut - only had half a seat belt... no horn. Big holes in the seats but it ran good and the radio worked... I got pulled over that one time I drove it. I told the cop it was borrowed because mine was needing work. He told me to tell the owner it needed a muffler. Only a muffler? He drove it another year with out changing anything. Yours is likely to go ok but yes check that safety stuff. If you don't feel safe get something else.

 

[Mattkcc]

Heck when I was a kid I loved the rust holes in the floor,it was fun watching the pavement rush by. Kind of missed them when we upgraded vehicles. I remember my dads 50's station wagon, the reverse gear was out so he would open the door and push with his left leg to get out of a parking spot. He looked funny in shorts his right leg was skinny and his left leg looked like a weight lifters.

 

[tx2sturgis]

Where are the holes? Front? Rear? Sides?

Most likely the rust is from trapped salty water kicked up into small holes that got bigger since the water had no way to drain...as opposed to water coming in from the roof or sidewalls.

Probably can be patched easily but if they are around the mounting points it could get tricky.

 

[steamjam1]

Never mind the floor... You can simply go get some fiberglass and cover it up, and then lay down flooring. You own a Dodge. You live in an area that salts the road. Go have the frame horns (The van's frame between the front wheels) inspected before you do anything. Dodge vans are infamous for steering parts, like the idler arms and steering boxes breaking off due to rust.

 

[Putts]

SInce it's a medium term fix, I'd find all the rusty bits, wire brush them, and then treat it with Ospho.

" When applied to rusted surfaces, OSPHO causes iron oxide (rust) to chemically change to iron phosphate - an inert, hard substance that turns the metal black. "

"Rust never sleeps" but Oshpho comes damned close to shutting it down. After treatment you can just paint over it or use adhesives to patch the hole. Use it anywhere you see rust.  Use gloves.

 

[VanMama]

So...the floor was the least of my worries. I'm glad I didn't get further into the build. The van is junk. The mechanic didn't even charge me because he felt so bad. He didn't even want me to drive it home. He said I am lucky I got from four hours away where I bought it especially going on the interstate withy there children in it. The steering box is almost completely off, rear brake line rusted, leak in field line, wheel bearings, idler arm, etc etc ETC. . I am bummed. I called the guy I bought from to warn h about the garage he got inspection at. He just put in $1,000 in work for his sticker in June...he gavee the receipts. I left him a message. Ugh. I'm supposed to be moving into the van with my kids next week. Looks like we are going the RV route if I can find a decent one in my price range. Thanks everyone for your help and advice. I'm SO SO GLAD I brought it in.

 

[Putts]

Oy! Sorry about the set back, hoping something very cool comes along for you.

 

[highdesertranger]

so sorry to hear this. rust is the killer of Dodge's. highdesertranger

 

[steamjam1]

Yeah. Steering boxes breaking off due to rust. Thats scary.

Good luck with finding an RV... They tend to not be so rusty because they really don't get driven in winter. Still. If its a Dodge RV, go have the front frame horns inspected before you buy...