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 I have seen numerous posts on the board in the past about POR-15, but have never used it myself.  For those that have, how bad can the rust be before POR-15 is no longer effective?  I have a friend who has an old soda cooler that was in his parents grocery store when he was a kid.  It is a non-embossed cooler that really has minimal value but is sentimental to him due to its history.  He wants to clean it up and use it in his basement.  Looking for a cost effective solution to the tub.  I would think this would be a good candidate for POR-15, some rust penetrations all the way through but some good solid metal as well.  Any comments would be appreciated.

I used POR15 on the bottom of my V81A in 2005 and it still looks the same. The sample was enough for me to do it another machine too (can't remember now). I still have some leftover in the back frig, but it is probably not good anymore.
It will level out and fill pin holes easily. Larger holes will need more attention. Maybe screw a screw in and POR over the screwn head. It comes with a couple of other preparations like a rust inhibitor and rust nuetralizer. It is a good product in my mind, just don't get it on your skin or you will be wearing it for weeks.

I agree with Tom.  I used POR-15 and some small fiberglass patches to fix the trunk in my Spitfire.  Buy one of their "starter kits" on eBay so you get the prep solutions as well (metal-ready and something else) and just follow the directions.  It will be more than enough to do pretty much any cooler out there.

I did my Spitfire's trunk 12 years ago and it still looks like the day I finished it.

Three cautions:
1) Use gloves - as Tom mentioned, it will adhere to your skin... forever.  (well, for a few weeks anyway)
2) Wear old clothes.  It won't wash out.
3) MOST IMPORTANT - use it in a very open (like outdoors) place and/or wear a good quality respirator.  This is not stuff you want to use in the basement or in a closed garage.  The fumes it gives off are very dangerous if inhaled.  POR-15 contains isocyanates, you do NOT want to breathe them in.

Good luck - post some pictures and let us know how it goes!

Jim

I learn so much on this board! What is POR? Is it like bondo? Or is it like a fiberglass patch?

I have used POR15 a few times myself.  Once on the interior floor of my Victor 4 door and the other on a Vendo56 square top cabinet floor underneath the tub.  In both cases it worked pretty well.  It is great advice to use it where there is good ventilation, but unfortunately for me my Victor was in the basement.   I used a respirator, but the smell remained in the basement for some time.   I had a few larger holes that I used POR15 putty for.  It hardens like a rock, but could not get it to smooth out that well.  In my case it did not matter as it was covered with the grates.   For my Vendo56 Square top I had the same issue with larger holes and used the POR putty again and again I had the same issue with not being able to smooth it out that well, but it was covered by the tub.  It is still holding well after about 1 year of use.   Another thing to mention is they have great customer service and we able to answer all of my questions.   Here is the link even know I know you could find it:  https://www.por15.com/crm.asp?action=contactus 

Hey Brenda - POR-15 is sort of a paint/sealant combination.  Extremely durable, a lot of car restorers use it for sealing the frame and other rust-prone areas.

Jim

Interesting! Thanks!

Is the POR putty sand able like Bondo, or more difficult to work with?

I have not worked with bondo before, but I can say the putty hardens like a rock.  They say you can sand it, but to be honest for me it was in places where I did not need to try that hard.

Is it "thin?" I.e. applied with a paint brush or is more of a paste? Where do you buy it?

The paint goes on with a foam applicator, it's thicker than your typical paint but not a paste.  I buy mine on eBay - their Starter Kit is only about $20 and should be  enough to do an average machine.  Here's an example, but there are a lot of vendors selling it:  http://www.ebay.com/itm/POR-15-45009-Gloss-Black-Starter-Kit-Degreaser-Metal-Prep-Brushes-Paint-Gloves-/191454690326?hash=item2c9396bc16:g:BGsAAMXQydtTMX35&item=191454690326&vxp=mtr

The putty is similar in consistency to bondo, but it dries super strong... like you could drill and tap it if you wanted.  I haven't used it but I don't think it is a direct bondo replacement because of how strong it cures.  I think it would be heck to try to sand to a smooth finish.

Jim

Thanks Jim!

I refinished the underside of a 20 year old lawnmower with the stuff. It works really good and is amazingly durable.
Just follow the directions carefully and remember it doesn't come off anything it touches. I have a  black spot on my garage floor.