Floor repair

[rogerowen]

I'm about to replace some rusty floor metal (O/S rear). I've cut out the worst stuff (avoiding spring hanger and cable/brake line). Originally I was thinking of welding a flat plate to the underside - but chickened out and bought a proper panel as it was only £20. Now I've got the panel - it looks like i'd be better fitting it from inside, overlapping some old metal - them rolling Marmaduke over on me Grumpy bars and then tidying the underside. I know butt welding would be neater - but I don't really trust my accuracy of cutting, and anyway it's an very out of sight repair. Any views/advice???[frame][/frame]

[rogerowen]

Here's the panel placed inside;[frame][/frame]

[mogbob]

Roger
I would try and keep the repair panel as large as possible , i.e. all of it ,in one piece ...for the extra strength that new metal will give.
Mark the perimeter onto the existing metal, chalk / masking tape / scribe ...whatever.Then clean up the old metal to ensure you have good sound metal to weld to.Otherwise reconsider the plan.Consider welding in small sections of metal off cuts, if there are " gaps ".The aim is a good / sound metal perimeter to weld to.

Butt is ideal but if that is a step too far for you .....do you have access to / own a joddler ? That would allow you to put a step in the repair panel in most places, so that the repair would "sit" in the hole you've created , with the joddled step resting on the edge of the perimeter.
If no joddler, do the lap joint and allow a reasonable overlap ( 1/2 inch / 13 mm ) of old / new metal, welding from above and below.Weld from the top first, weighing down the panel, either with your own body weight or something heavy.Bag of sand / compost.
Wire brush/ clean up the welds meticulously and wipe in generous amount of sealant , to keep out the moisture.Body filler another solution, if you're going for the perfect finish.
Underseal / paint your choice to make sure everything is watertight and protected from the elements.You get the general idea, otherwise guess who will be doing the repair all over again ?

The usual safety reminders .. make sure the electrical loom , brake lines and petrol line are nowhere near or are suitably protected / shielded.No petrol leaks / smell present ? Weld in short bursts 1 inch/ 25 mm and move to a different area allowing the weld to cool off..not creating distortion.Put a jack under the area with a thick block of wood to " just support " the join.Not " so high " that it puts it out of shape.

When you go underneath , plenty of axle stands/ ramps / spare wheels / wheel chocks , so the car doesn't fall on you.A second pair of eyes is useful but at the very least,let someone know what you are doing.Some means of getting attention , in case of emergency is good.

Bob
P>S ignore some of the remarks, I see you've got a roll over piece of kit, lucky man ! No molten metal falling on you then ??

[rogerowen]

Great tips Bob, many thanks.