Our POR-15 Troopy Project

The Carby Shop has recently added another vehicle to our ever growing collection - a very rusty 1995 Toyota troop carrier.  We will be using it to travel down the west coast of Australia and it seemed like the logical choice, I think we might have a lot of work to do.....

A common problem with the Troop Carrier model is rust.....

With floor pans like this we were going to be stopping the car Fred Flintstone style....Yabadabadoo!!!

The rust is everywhere......

How much did we pay for this car?????

Driver's side floorpan removed

RHR outer 1/4 panel removed, check out the rust on the inside panel...

More rust removed...

This is what's left of the LH side floor panel.....

Here we have a pair of replacement floor pans. Before applying any paint you must remove any oily film or grease. Even if you're fairly sure that your item is clean, use POR-15 Marine Clean to be absolutely certain.

POR-15 Marine Clean is the best paint prep for removing oils, waxes, silicon's, paint stripper residues or any other oil or grease contamination before rust removal and painting.

Metal Ready creates the ideal anchor pattern for POR-15 Rust Preventative Paint and is safe and easy to work with. After thoroughly degreasing your surface apply Metal Ready to both neutralise and remove rust. Surface rust removes in minutes. Allow up to half an hour and repeat if necessary. Do not leave it on for long periods. Rinse off with water and allow to completely dry. After drying it will give a salt and pepper look. This is normal with the Zinc Phosphate adhering to the metal.

POR-15 Rust Preventive Paint stops rust and corrosion permanently. It is unlike any other paint coating you have used before. It's surface tolerant characteristics means it loves corroded and porous surfaces like rust, corroded aluminium, sandblasted surfaces, fibreglass and even concrete. It will seal them with a ceramic like, rock hard finish that won't crack, chip or peel.

The floorpan has been treated with POR-15 and welded into position, notice the replacement panel matches the original floor plate?

The rust on the inside panel has been removed and then the repaired section has been treated to be prevent the rust returning.

Thankfully the RHR wheel arch only needed a minor repair.

The outer sill panel, fitted and ready to be treated with POR-15 Rust Preventative Paint.

The rust repair panels made the job a whole lot simpler, we replaced both front floorpans, the outer sill panels and the LH rear lower 1/4 panel (outer).

The Carby Shop can supply a full range of rust replacement panels for most makes and models, please give us a call to discuss your requirements.


Imagine how long it would take to fabricate this panel from scratch.....

Once the floor pans were fitted we also treated the ajoining areas with POR-15 Rust Preventative Paint to ensure the rust would not return.

The final prep being carried out before painting.....

To prevent the rust returning we decided to seal the door panels, chassis rails, inner sills and inner 1/4 panels with Dynax S-50 Cavity Wax.  Dynax S-50 is a high-performance anti-corrosion wax that provides exceptionally long-lasting protection to steel surfaces. It creeps into welded seams and seals surface defects. Dynax S-50 forms a soft, brown, wax-like film that self-heals in the event of disruption. It is also able to arrest existing corrosion and to provide long-term protection to pre-corroded and corrosion-free surfaces.

The advanced metal seeking anti-corrosion molecules which form Dynax S-50 are able to displace water, so even damp surfaces can be protected, these same molecules arrest and prevent corrosion even on already rusty surfaces and provide remarkable self-healing abilities if the film is damaged. Whilst Dynax S-50 is primarily a cavity rustproofing compound it’s also able to prevent corrosion in a multitude of mud traps and water collecting voids. Dynax S-50 has been used with superb results to protect voids and cavities in steel boats, vessels, off shore installations and other steel structures subject to severely corrosive atmospheres.

We were applying the wax in tight areas so we decided to use the aerosol version although Dynax S-50 is available in 5 and 200 litre containers so it can be applied by using a brush or roller.

The pressurised giant-sized Dynax S-50 aerosol dispenser accepts interchangeable heads: The 60cm cavity injection lance has a brass, precision fluid-tip drilled radially to deliver at high-pressure, a dense, finely atomised circular mist of Dynax S-50 ensuring 360 deg coverage of box sections and cavities. For accessible areas the extension tube is removed and a solid-cone spray pattern actuator simply clipped in its place.

Dynax S-50 will provide excellent protection at a wide-range of film thickness - aim to achieve a uniform dry-film thickness of around 50 microns. The tolerance of the material to maintain protection at very low film thickness makes Dynax S-50 the ideal choice where surface inspection is not easy or where uniform coatings are simply not possible.

Fully repaired and painted....

Looks like a new car....

The finish is amazing, the rust is gone and the panel / paint work is perfect.

Who would have thought this was the same Troopy?

Special Thanks

The Carby Shop would like to thank the following people for their huge contribution to get the Troopy completed to the standard it is.....

Barry Fowler Motors (Mechanical Repairs) - 0427167479

Kym Russell (Panel Repairs & Paint) - 0450646417

Grant Mauger (Paint Assistance)