Interior of Roof Box Rusted

[outatym2001]

I added text to the pictures describing the tool I made to apply POR 15 inside my rusty roof box.
The stainless steel Roof Panel part 100204 (T Panel) covers the black area seen in the pictures.
Pictures of the Roof Panel can be seen in this thread.
T-panel / insulation replacement
http://dmctalk.org/showthread.php?58...on-replacement

[aludden]

So, what did you do exactly? You used the tool you made to brush POR15 on the inside? You went through the access hole where the connectors are? What about the wires inside, did they just get painted as well? Could you have spray-painted the POR15? What about something like Waxoyl? Is POR15 better?

Lots of questions! I haven't found any other references other than the link you post, and one in the UK group, or even pictures or drawings of the roof box except for the one sold by delorean.eu

Thanks!
Alex

[outatym2001]

Alex, those are all very good questions.
I was hoping it was self explanatory that I used the sponge as an applicator to apply the POR15 inside the roof box. POR15 is very thin almost like water but when it cures it’s as hard as a rock and it’s impossible to scratch it because it is so incredibly tough.
You MUST clean off the lid and the inside edge of the can or else the POR15 will seal the lid to the can that is if you want to save some POR15 for later.
The entire insides of the roof box is rusting on my ’81 DeLorean. The roof box is some kind of zinc plated steel. And the steel cover plate that seals this access hole was also rusting so I had it black powder coated at the same time as my three black windshield trim pieces.
I couldn’t get a camera inside of it to take a picture since the clearance is only about one inch (2.5 cm) from top to bottom where you enter through the access hole.
I got a paper towel wet with denatured alcohol and wiped the POR15 off of the wiring before the POR15 cured.
I never did find a nozzle long enough and skinny enough to spray the POR15 inside the roof box that is why I chose to make a sponge applicator.

I had never heard of Waxoyl until now. I used POR15 since DMC Northwest sells both black and gray and each 4 fluid ounce (113.6 mls) can is $12.95. I used three cans because I couldn’t see inside as I was applying it and didn’t notice where I had missed.
I wish I had seen this video on how to apply Waxoyl then I would have never needed to make my sponge applicator. In the video they have the perfect long skinny spray applicator for the large surface area inside the roof box.
Waxoyl Application Guide
http://www.youtube.com/watch?v=zcNP4INYEMI

After some research online the equipment to apply the Waxoyl is much more expensive than my hand made applicator. I used a super sharp knife to cut the foam and a cordless drill to drill the three holes in the metal bar. Of course with the Waxoyl you can order the equipment online and have it directly shipped to your home. BUT you also need an air compressor and I don't have an air compressor.

[aludden]

Thanks for your reply Mark. It was mostly self-explanatory, but your additional comments are very helpful. I was thinking of the spray-can Waxoyl, or a similar product which has a long nozzle: http://www.eastwood.com/ew-anti-rust...zle-amber.html

I know mine is rusty because the seal separated behind the torsion bar, and I can see the rust there, so I want to apply something before I seal it back.

Thanks for the pictures! I always understand things better when I see them.
Alex