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I would like to know the best course of action for dealing with a rusted passenger floor pan. The coverage does not seem to be of serious concern “I think” to warrant a total replacement, so I am weighing options to cut out the rust and rivet sheet metal in place, or mig weld which I attain zero experience with but understand the basics of it through online research.
I would dread having to have a shop replace the whole pan due to cost however if that were truly necessary then so be it.
Cutting out the rusted metal and welding in new metal is the right way to do it. Reproduction left and right floor pans are available, but you don’t need to replace the entire floor. You can cut the sections you need out of the replacement pans and just patch what is needed. Grind the welds flush on the underside and leave the weld bead intact on the top (under the carpet).
Cutting out the rust is always the right thing to do.
The structure still looks fairly strong though, so if you are looking for a cheaper option, you could do yourself, check out POR-15 and for your case there power mesh. https://www.por15.com/POR-15-Power-Mesh
If you use it with the POR-15 product, it would be a good fix and likely last forever. The key to its use is following instructions to a t, clean up rust, the degreaser, acid etch and two coats with mesh on inside, two coats on outside and it will be very strong, as well it capsulate the rust so it cannot expand.
Cutting out the rust is always the right thing to do.
The structure still looks fairly strong though, so if you are looking for a cheaper option, you could do yourself, check out POR-15 and for your case there power mesh. https://www.por15.com/POR-15-Power-Mesh
If you use it with the POR-15 product, it would be a good fix and likely last forever. The key to its use is following instructions to a t, clean up rust, the degreaser, acid etch and two coats with mesh on inside, two coats on outside and it will be very strong, as well it capsulate the rust so it cannot expand.
That’s an effective solution I hadn’t thought of! Great recommendation and might just be the way to go.
Cutting out the rusted metal and welding in new metal is the right way to do it. Reproduction left and right floor pans are available, but you don’t need to replace the entire floor. You can cut the sections you need out of the replacement pans and just patch what is needed. Grind the welds flush on the underside and leave the weld bead intact on the top (under the carpet).
I agree this is the 100% proper way,
But at that point, knowing I had bought fresh pans I’d just take it to a shop for full replacement. Any cheaper alternative to squeeze 5-8 more years out of the floor would be best suitable for me now.
