Rusted Raypak Heater

Yes it's safe to operate. Sadly this is very commonly seen on the natural draft style Raypak heaters. Once the corrosion starts there's really no way to stop it. They basically rot themselves out from the bottom up. It has to do with the combustion condensate dripping downwards and pooling on the bottom. Also, any ground moisture in contact with the bottom will accelerate this process.

I've never heard of anyone just replacing the bottom. I would imagine it's not at all easy. Perhaps @swamprat can comment on it.

Nanos203 said:

Thanks. Can I place another piece of metal over it? Or apply a paint to show the corrosion? But I guess if it’s safe to operate there is no point…

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That bottom area sits right under the flame tray. While not directly heated, I imagine it gets hot enough down there to not be good for paint. I would honestly not mess with it. At this point, you're way past any remediation of that metal surface. Keeping it as dry as possible, if at all possible, is the only course of action now.

Perhaps others will have better ideas ...