94 seatbelt floor rust project with pics.What do you think ?

[540itouring]

Hi i discovered rust where the seatbelt plates are fitted onder the floor. The water and rust gets between the plates and the floor and then eats into the floor. The car looked fine from under the car but found the rust when i pulled the carpet up.

I cut out all rusted parts abd got a new welder and had a few tests and started the repairs to the floor. I have found the problems with the galvanised floor not being easy to weld and hard to remove this without making the floor even thinner . I am not rushing this but i am pleased with the results so far. This is a link of the pics and wonder what you think ?

The patches have been butt welded and ground down and plan to treat all bare metal with the por 15 after the metal ready stage and thing this will make a good job and will not be seen from under the car once undersealed on top. The last patches i will sand down more before welding and hope this removes all galvanising to make the welding easy and no smoke !
the weld i have is a esab caddy c200i and am using Argon /C02 /O2 shielding gas and 0.6mm wire .


http://tinyurl.com/chkqcjg

[XjRestorations]

Nice work there.
Take your time, and you get a nice end result

[dhdove]

540i

You have my sympathy, my otherwise solid black Celebration failed it's MoT with totally rotten floors in this area. It really is a problem on the old girls.

Looks like you'll get a result though, well done

TonyS