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Rusted floor pan, how do I get off the carpet?

9K views 29 replies 10 participants last post by  Heavend 
#1 ·
I recently discovered some rust on the Floor Pans (?), well some rust is a serious understatement. The rust have created two holes on both the driver side and passanger side, just for the record that would be two rust spots, so their not connected. Luckely I've got a welder available and some knowlege on how to weld, but I were wondering if anyone have encountered this before and have some pointers? Also if anyone know of any step by step instruction on how to remove the carpets to get to the other side of it all and see how it looks from there and to start welding.
Do I have to remove the seats to get to it? the actual holes and rust don't seem to be under the seat, but maybe I've got to remove it to get the carpet out?

English isn't my primary language, so I'm not all that familiar with the terminology etc. So if something I said didn't make sence just ask ;)

Any help would be greatly appreciated!
 
#2 ·
If they're in the usual place, you don't need to take the seats out.

Remove the b-pillar trim, then prise up the plastic trim above the sill (there might be some screws to undo as well - can't remember!). Then the carpet can be pulled back.

There are wiring looms either side, so make sure these are out of the way of the heat from the welder!
 
#4 ·
Thanks, the trim above the sill you speak of... should I remove it with force? I've unscrewed the only screw I were able to find, but it still seems to be stuck at two points. Can't see any screws or anything around them so perhaps just some clips, but a bit scared of using force without knowing if that's the right thing to do ;)
 
#6 ·
Rusty 156's are becoming very common. :(

I have one with holes as well, but it isn't as bad as Chris' example.
 
#7 ·
Goes to prove that what most people think of Alfa Romeo is probably true, poorly made rust buckets (galvanised my ****)! Never had a rust problem with my old Toyota's, don't think my Alfa will last half as long as my previous 20 year old Celica, this had not a speck of rust and no silly anti roll bar problems and 30k cambelt replacement intervals!
 
#8 ·
Alfa's built in the Arese plant such as the 164, GTV, Spider, and 166 don't rust as much as the 156, 147 and GT which are built in a plant near Naples.

We should also remember that some 156's are nearly 13 years old. I don't think rust on a 13 year old car of any make is totally unexpected.

My dad had a 1986 Toyota Supra 3.0 many years ago, and that suffered bad rust inside the rear wheel arches. (it was 8 years old at the time)
 
#9 ·
symon said:
Alfa's built in the Arese plant such as the 164, GTV, Spider, and 166 don't rust as much as the 156, 147 and GT which are built in a plant near Naples.

We should also remember that some 156's are nearly 13 years old. I don't think rust on a 13 year old car of any make is totally unexpected.

My dad had a 1986 Toyota Supra 3.0 many years ago, and that suffered bad rust inside the rear wheel arches. (it was 8 years old at the time)

Touchwood but my 98 156 is totally rust free at the moment.
 
#13 ·
You have clearly missed my point! I understand not following the majority, I have spent my whole life not conforming and always taking the alternative path, normally at my own cost! The point I was making was are the rumours about Alfa justified? Yes it's great to have a car that makes you feel good and smile, but the motor car has been in production long enough to have ironed out the obvious floors to it's design I.e. rust, have we really progressed? I don't think so.....
 
#15 ·
You have tp remember that the vast majority of people have no interest in cars. Those types of people automatically follow the herd and buy Fords, Vauxhalls, Hyundais etc because they are "Safe" buys.
 
#16 ·
Why do people have no interest in cars if they buy Fords, Vauxhalls etc? Your statement makes no sense! You can be interested or an enthusiast in cars with any manufacture you buy! My previous point was that, the motorcar has been in production for a very long time, you would think that by now rust would be a thing of the past! Lastly I think Alfa should count themselves lucky to have such a loyal following as on this forum, that don't care about all the faults and always react by saying 'Alfa's are a drivers car' or 'Its about the way it makes you feel'.
 
G
#18 ·
So few on the road?
Take the 156 for example - there weren't enough of them made to justify a Haynes manual ;)
Rust?
Steel + the state of British roads / weather conditions / salting of roads = corrosion for any marque :(

Get over the stereotyping opinions of 'top gear' viewers & enjoy Alfa ownership
 
#22 ·
I think it is pot luck.

My last 156 was 1998 built but 2000 registered and was totally rust free.

This one is 1999 built and 2000 registered and requires lots of work.
 
#26 ·
Not a comparison as such...just pointing out that that there are worse cars out there! (which we all know ;))

A lot depends on where they're kept/how they're treated though...

Having said that, all the GTVs I've owned (2x1996, 1x1998) have been completely solid underneath. I can't say the same about my 156...or my BMW...or the vauxhalls I've had!
 
#30 ·
My 156 had a rusty left rear floorpan. I found a 145 (2 door) and it has the same profile floor. Interestingly despite being older it was in perfect condition. More interestingly the steel is 0.8mm in the 156 and 0.9mm in the 145, and much stiffer as well, suggesting a different grade of steel. The 145 was better protected. In my car I believe the rust was due to a leak letting water pool under the carpet.
 
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