Well, after I had the full S&W racing subframe kit installed in the car I was able to begin the tedious task of redoing the undercoating on the vehicle. I jacked up the car, laid down some plastic on the ground, bought a whole assortment of wire wheels, sanding sheets, wire brushes, etc and got to work. I began by removing a bunch of the rubberized undercoating using a heat-gun and a putty-knife/scraper combination. This took a while and sure was messy. I then got my hand-drill and worked with the different array of wire wheels. I had to rip off all the remaining undercoating, factory paint and primer...so that the metal under most of the car was down to complete bare sheetmetal. Some areas were very difficult to reach. (for this project I concentrated on everything rearward from the firewall and rear of the engine..I did not drop the rear end and did not drop the fuel tank...when I replace the rear end, I will sand and undercoat above it).
photos below show the exposed bare metal under the car. the black bars are the subframe kit.
after the metal was stripped down, i went to the POR-15 headquarters in Morristown Nj and checked out a bunch of their products. I bought the "marine clean" metal cleaner, the "metal-Ready" phosphate metal prep solution, and a quart of semi-gloss black POR-15 metal undercoating. anywhere this paint is, even if there was rust to begin with... it will never grow; ever. applying this stuff was messy. as it says in the instructions .. if it gets on ur skin, get it off asap. otherwise it wont come off..it has to wear off. i did two complete coats, using a variety of hair and foam brushes. turned out awesome and it is strong too. total cost for the products was under $60, but it will only work correctly if you follow the exact directions.
i also puilled out all the floor drains and whatnot and coated them, then sealed everything up with some RTV.
I also sanded down the interior floorpans a bit and coated them with a different product. I used a similar product to POR-15, but since the interior floor should never see any liquid.. I went with a product I got for free from a mechanic buddy of mine - Hammerite Rust Cap, gloss black - . It worked great. It was thick to brush on, but I can tell it is solid too. Pics are kinda blurry - sorry, but you can get the point.
