I've finally gotten a few actual free days to do this job I've been wanting to do for a long time.
1. Removed seats to refoam and re-cover them.
2. Took out original carpet (autumn leaf) and washed it in the washing machine (Don't tell my wife). It came out looking great and is still in very good shape. I'm not really sure I need new carpet.
3. I had a new carpet set from Moss in heavier weight (sound proofing, after all) with moulded center tunnel I bought a year ago on sale. So, I guess I'd better install it.
4. Wire brushed all surface rust on floor, heat gunned and scraped off some tar material the DPO put on (Try that on a 95 degree day!). I used Eastwood's 'Rust Encapsulator' on all metal areas which had had surface rust. Now the floors are flat black.
5. Started installing foil-covered insulation (Second Skin 'Damplifier,' same as Dynamat, but half the price) all over the interior for better heat and sound proofing.
Now for the questions:
1. Is 'Rust Encapsulator' enough? Should I have used POR-15 or some other product? It was pretty minor surface rust. I haven't covered the floors with the Damplifier yet so I have time to think this over.
2. Is Damplifier enough to get real benefits -- or do I need to top it with some kind of liquid heat/sound proofing? I'm not too excited about painting over everything with some 'goop'. Might make me a DPO.
3. What carpet pieces should be glued (I assume all vertical pieces) and which left loose? Will double-sided tape work as well as glue?
4. What glue is best? 3M spray glue, I assume.
5. I'm not looking forward to putting the seats back in. I did that once. PITA to get the bolts lined up and back in. Anyone know what size front seat bolt it would require to screw up from the bottom to align the seats and get the rear bolts started?