Rust Repair - Cut, Weld, and Fabricate New Floor Plates

Task Description

Major rust repair work involving cutting out rusted sections and welding in new custom-fabricated plates. Primary focus on four footwell areas plus various other rust spots throughout the vehicle. This is extensive metalwork requiring significant time and skill.

Parts Required

• Sheet steel (1.2-2mm thickness)
• Welding wire/rods
• Welding gas (if MIG)
• Primer paint
• Rust converter/neutralizer
• Seam sealer
• Cavity wax
• Zinc primer
• Cutting discs
• Grinding discs
• Welding blanket
• Fire extinguisher

Tools Needed

• Welder (MIG preferred for sheet metal)
• Angle grinder
• Cut-off tool
• Sheet metal shears
• Hammer and dolly set
• Sheet metal brake (or access to one)
• English wheel (optional)
• Clamps and magnets
• Measuring tools
• Cardboard for templates
• Safety equipment (welding helmet, gloves, respirator)
• Wire brush and prep tools

Procedure

Assessment Phase

1. Thoroughly inspect all areas for rust
2. Probe with awl to find extent of rust
3. Mark all areas requiring repair
4. Prioritize structural areas

Footwell Repairs (x4)

1. Remove seats and interior items
2. Cut out rusted sections with clean margins
3. Create cardboard templates for new panels
4. Transfer templates to steel and cut pieces
5. Form panels to match contours
6. Test fit and adjust as needed
7. Clean all surfaces to bright metal
8. Tack weld panels in place
9. Complete seam welding
10. Grind welds smooth
11. Apply seam sealer
12. Prime and paint

Other Rust Repairs

1. Address each area systematically:
   • Door bottoms
   • Rocker panels
   • Wheel arches
   • Chassis mounting points
   • Any structural members
2. Follow same cut, fabricate, weld process
3. Ensure structural integrity maintained

Rust Prevention

1. Treat all repair areas with rust converter
2. Apply cavity wax to enclosed sections
3. Use zinc-rich primer on all bare metal
4. Seal all seams properly
5. Ensure drainage holes are clear

Notes

This is the most time-intensive task on the list. The 40-hour estimate assumes good metalworking skills and proper tools. Consider professional help for structural areas if unsure. Work in sections to keep vehicle mobile if needed. Proper rust prevention during repairs will determine longevity of the work.

Safety is paramount - ensure proper ventilation, fire prevention, and use appropriate PPE at all times.

Progress Updates

Task updates will be added here as work progresses