Time to weld! Got to say I am really nervous about this. I practiced a little more on the bits I cut out of the floorboard.
When I positioned the passenger side floor patch I found this. The floorboard has been bent down a bit because of the giant rust hole.
I shimmed up the floorboards using scrap metal and wood.
That is much better.
Time to make this happen. I used anything heavy I happened to have around to try and hold the patch down tight. Then I tacked it. To keep the temps down I blew each tack with compressed air.
Then I just kept tacking. I had one blow-through on the transmission tunnel. Metal was rusted thin and just melted away. I filled the hole with with weld a little at a time. Shielding gas is running low so I switched over to the driver’s side.
I used the paper template I cut the patch from to grind the paint and rust where the patch will be welded. Got the lines all lined up. Floorboards were bent here too so I used whatever bits of wood and metal I had sitting around to shim up the floorboards to get the gaps tight.
Same drill here. Tack, tack, tack. For some reason this side was not going as well. I found the wire was not feeding very well. Cleaning the feed rollers and nozzle made everything go a lot better. Once the stitch welds got close together I tried to run seams between them.
Well that looks like crap. I need more practice at this. Sometimes the welds went perfectly, others horribly. But in the end I got the plate welded in. Then I went back to the passenger side to finish it up.
Then I ran out of shielding gas. I will have to get more before I can finish this up.