Rusted Out Floorboards

[Bluerobin]

Crabby's car failed inspection, due to about 5 holes in the floorboards under the front seats. We have until the end of the month to replace or fix the car.
Is it worth it to fix the holes or is this the start of the inevitable decay? Is it expensive? Mechanically, the car is fine.

[tskeeter]

The cost depends on how you "fix" it. The most proper way would be to take the car to a body shop. Have them cut out the floor and weld in a new floor pan. Doing the repair this way helps maintain the structural integrity of a unibody car. My guess is that this would cost between $500 and $1,000 if the work doesn't involve too much welding and the fuel system doesn't have to be removed to do the work. You should be able to get a more accurate idea of the cost by giving a local body shop a phone call.

If you only need to nurse the car along for another year or so before it goes to the junk yard, there is a lower cost, but less effective approach. Get some sheet metal and roofing tar from the home center. Coat the floor area with roofing tar. Attach the sheet metal so the holes are covered. Spray the entire area with a heavy coat of rust proofing spray from the auto parts store. If the only concern the person doing the vehicle inspection had was exhaust seeping into the car, this approach should address that concern. Cost to do this should be about $50 if you do it yourself.

But before I did anything, I'd check the entire floor area of the car for rust damage by jabbing it with a screw driver. If the rust damage is more extensive than is indicated by the holes you can see today, I'd question whether it was time to junk or part out the car rather than fixing it.

ETA: I check prices on a floor pan for a Chrysler Sebring. The cost from an internet supplier of OEM parts was about $260. Then add labor. If cross members or reinforcements are also rusted out the cost would be higher.

[Bluerobin]

Thanks. I like not to be rushed into buying a new car - this was a surprise. Despite being a 98, the car has no other rust. We are looking if there are no definite new cars by about the 25th, then we will consider fixing.

[Bluerobin]

Rick and Skeeter, thanks. Too much to get into on a 13 yo car and we found something that fits. We got a new car.