We probably should have given up on the car but what the hey... Here are some pics of the floor patching we have been doing. First some holes and the patching.

For the patching we used some heavy gauge metal (18 ish). Full perimeter welded with "spot" welds reproduced where required.

 

Once the patching was done the floors were painted with chassis saver paint and then seem sealed.

After that we sprayed them with truck bed liner. I predict that they will never rot again, OR someday I will be cursing what we did while patching them again...

After-all I was cursing the fact that 20 years ago we coated them with rubberized undercoating. It was a PITA to remove.

 

Looks good...What type of welder do you use to attach those patches....I am guessing it is a wire feed with gas for heat...All I have is an old 220V stick

 

We used a MIG welder (~250 amp Miller) with a low "heat" setting.

 

Nice I just patched the EXACT same places on mine.

 

For the front floor patches, this is the second time I have done them on this car in the exact same spot (the last time was ~20 years ago). I found some leaks in the cowl and where the strut towers meet the firewall (also patched these areas) so water was pooling here. (of course the usual T-Top leaks as well).

 

Sounds familiar

Looks about the same huh?