1996 HZJ75 Rust repair help

[Slotosea]

Anyone familiar with OEM internal finishes of the hzj75?

Finally planning to tackle some rust repairs before a camp buildout in the back of the Troopy and have a couple questions.

My driver and passenger floorboards seem to have a rubberized seal over the top of them, is this OEM or aftermarket? What is it? I have new floor pans I’m thinking of welding in and adding sound deadener to (Kilmat knockoff).

What is the OEM finish on the back floor? Currently there is a black coat that I assume is from the previous owner and thinking I should grind it down to clean metal then prime and paint it.

A couple spots seem to be seam sealed shut from the previous owner without any new metal, I’m planning to weld in new metal, any advice in painting the underside that’s hidden by the frame (without removing the body)?

Gutters have good amount of rust where old rack was mounted, how do most people tackle this rust?

A couple rust points through paint under gutter as well.

I know she’s got some wear, but looking to put in some work to get her 80% of the way there to last another 10-20 years.

 

[gilmorneau]

Anyone familiar with OEM internal finishes of the hzj75?

Here's an original, unrestored Troopy passenger side front floor. The sound deadening tar sheet is original:

Driver side:

under the seats:

And the rear floor/cargo area as it came from the factory:

Gutters have good amount of rust where old rack was mounted, how do most people tackle this rust?

This can be insidious. The weight of stuff on roof racks can flex the gutter and roof to the point where the seam sealer cracks. Moisture gets in, rust inevitably follows. The roof along the gutter seams can also rust from the inside. Cool air outside, steamy humans inside can lead to condensation that drips down along the top interior of the roof to the inside of the gutter seam where rust forms.

Best way to deal with it is probably to remove all the old seam sealer and assess. Clean, treat, or weld as necessary, then seal and paint. Might buy you a few years.

 

[jblueridge]

The asphalt stuff on the floorboards can be frozen with dry ice. It can then be smashed into chunks and bits and removed.
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