Some here may recall I'm a huge fan of POR-15 products, used it on a 2003 E-250 EB while re-fitting the bare cargo body into a work van but with a rather significant insulation, lighting, factory-style hot coolant rear heater, etc etc. I had minimal rust in the rear cargo area but somewhat significant front floor rust that I wanted to address. I was satisfied with the results, owned that van from May 2012 until sold March 2020. I didn't have time or honestly the interest to partially dismantle parts of the interior build to assess how the POR-15 had held up by itself and in conjunction with other remedial steps taken to stop rust from reforming.
None the less I'm still a huge fan of the product, still highly recommending it's use to those of us looking to extend the life of our vans. Now I own a 2005 E-350 extended body, formerly a senior citizen wheel chair lift equipped transport for a retirement home. It has some rust issues lower left quarter panel between the rear bumper and front of the wheel well.
During the initial exploration of how much rust was hiding under the factory finish I hatched a plan to hopefully deal with this "permanently" as in never having to re-do anything for the remainder of this van's life under my ownership. I discovered two large areas with significant rust holes that might have been best repaired with new metal patch panels---that might still happen come 2024 if my DIY repair doesn't hold up. Fortunately there are aftermarket panels for this body which is good to know.
I don't have any photos of my still on-going process as I was in too big a hurry to complete things.
( I became frustrated as my haste led to several "mishaps" that could have been completely prevented had I simply slowed down a bit. They were somewhat easily overcome but should have been top of mind from my previous experience with POR-15.
At any rate along the way I've added to my general knowledge base and familiarity with other products from POR-15 that might interest others here. I've used these myself so speak mostly from experience. Onward.....
First recommended product is the Power Mesh repair fabric: https://por15.com/collections/access...cts/power-mesh
. Much thinner than traditional fiberglas mat used in tons of bodywork, its applied with POR-15 paint if desired so cuts down on a lot of work. The holes I repaired were about 3-4" diameter which makes these repairs a bit on the questionable side but time will tell how well it does (or does not) work. Good stuff, sometimes "out of stock" but someone somewhere will have it in stock.
Next up is the Patch Filler & Seam Sealer, also often "out of stock" but also available somewhere on the 'net: https://por15.com/collections/filler...products/patch
According to POR-15 this is simply their paint thickened and in a tube with the same specs as the paint. It's a from of body filler in that it is sandable and once fully cured compatible with most other automotive body refinishing products. Because its just POR-15 paint its very tenacious gripping metal, mostly easy to use---we'll see how well it holds up in my application over the next 6 months or so.
It is NOT flexible so keep that in mind---might not work too well on rain gutter repair........
Another filler product is JB Weld who now have an extensive line of two-component epoxy-based materials that far exceed their "cold weld" product most of use have used. They are very worthy of investigating today: https://www.jbweld.com/products
I'm using their 50165 as a robust filler because in the syringe form its ease of storing and dispensing just when needed is highly convenient.
It too is sandable but will require a bit more work to achieve a smooth surface suitable for painting--I'm yet to discover how to best work the fully cured material into a surface the POR-15 Silver paint will cover adequately for my hoped for finished results.
I did mention one haste induced "mishap"----it involves using the Silver paint and not
assuring it was thoroughly
mixed while still in the can. This particular "color" is very high in solid content which can and will settle to the bottom of the can, become some what very thick and needs to be dragged off the bottom to mix it completely with the binders and solvent already in the product. I use one of these things: https://www.amazon.com/ALLWAY-HMQ-At...737783409&th=1
They're available most anywhere paint preparation products are sold, the Amazon link only for illustration purposes.
Another word of caution is thoroughly remove ALL POR-15 from the lip of the can where the lid rests when closing up the product for any time at all. This stuff becomes an adhesive and will almost weld the lid to the can!!!
So I hope this is useful or interesting to anyone facing rusty body work and repair. I'll answer any questions I can.