I bought a project car. The hatch leaked for sometime and i wasn't able to lift the carpet yet but i got a quick glimpse of atleast some minor-deep surface rust. I dont think anything has rotted through but i'll look when i can dismantle the interior.

Besides sand blasting and using a dual sander/grinder

and to patch up any sections that need to be removed and replaced just use a blow torch and weld in sheet metal?

Did i miss anything? besides once finshed prime and paint.

Any other ways of going about it?

I'm not going for factory look just a solid floor pan.

So any other suggestions let me know thanks.

 

Don't use a sandblaster or grinder...both are very aggressive and you will end up blowing away/grinding away too much metal if it is already thin.

You can do this two ways:

Cut out the rotten areas and make them square, going back to clean metal. Then, fabricate a patch out of sheetmetal and weld it in using a Mig welder, not a blowtorch.

Or, you can clean the metal with a wire wheel on a drill and some sandpaper or wire hand brush for the tight areas. Then, spray/brush the whole area down with Ospho acid and let it sit overnight. Put down two coats of Master Series silver. Use some fiberglass mesh and resin to cover your holes, let that dry. Then hit the whole area up with some Master Series black.

Obviously, the first method is the most professional, but you gotta work with your skills and budget.

 

that is the kind of advice i was looking for. A friends uncle has a welding shop with all kidns of welders. free labor right there. But where can i purchase taht ospho acid and what kind of gloves or protection do i need while using it and do you know how to clean it up and dispose of it properly?

 

also quick questiion.... what is below the floor pan??? is it the ground? or is there a separate undercarriage layer or metal?

i have seen the under carriage. Only minor surface rust on sharp edges which i can easily fix.

The reason I ask is because i'd rather sand down or rub down to real metal if I can. Instead of patching it which meaning I have to real coat that section of the under carriage if it is only one layer.

The previous owner let the car leak and sit for a yr n half. I'm not sure how much the carpet and seats absorbed over the years and how much the floor pan really got. I have the car under tarp now and I got the engine running much better with some minor tuneup and maitenence.

I'll keep you guys up to date.