Hey everybody,

I am still blasting the underbody of my car. Moving from rear of the car forward, started doing the floor pan under the driver today. Everything was going great until I accidently hit the switch on the light I was holding.

Once the light went out, I saw several pin-size rust holes where I've already blasted (light shining from the other side). Then as I kept going I also blated away another rust hole about 1/4" in diameter.

Besides those few holes here and there, floor pan seems to be in more or less solid shape. So what should I do here? I am assuming sealer won't work. Should I cut out the pitted areas around the wholes and attept at patching metal? I hope these don't actually call for replacement of the entire floor pan.

 

fiberglass mat and resin. Then POR-15 or the like, then rubberized undercoating/gravel guard.
Unless it's a giant hole, it won't affect the structural integrity noticeably. The smaller holes you can just use short or long strand fiberglass filler.