Battery Box and Front Boot Corrosion
Symptoms
The front boot floor, particularly the battery box area on the passenger side, develops severe corrosion. The metal becomes soft, perforated, and eventually structurally unsound.
Cause
The battery sits in a steel tray in the front boot. Acid vapour from the battery corrodes the tray and surrounding panels. Water from blocked windscreen drains and poor sealing pools in the front boot and accelerates the process. The front boot floor is single-skin steel with minimal corrosion protection.
Fix
Cut out the corroded metal and weld in repair panels.
Pre-fabricated battery box repair panels are available from specialist suppliers (914Rubber.com, Stoddard).
The surrounding floor sections may also need patching.
Cost: $1,500-$3,500 depending on severity.
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