Rust holes in the floorboard are a common problem in classic cars and trucks, especially in areas of the country that salt roads in winter. If you're restoring or rebuilding a vehicle, it's important to properly repair such holes. The longest-lasting repair method is to cut out the rusted area and weld in a sheet metal patch. Fortunately, specialized tools are available to make this a doable task for the dedicated do-it-yourselfer.
Instructions
- 1
Remove the floor mats and carpet. Wire brush the metal to clean and remove loose rust.
2Mark a square or rectangular area to encompass the rust holes. Mask the border with tape.
3Drill a hole in one corner. Cut the metal out of the marked area with the nibbler, starting at the hole. Crimp the cut edge all the way around the hole with the panel flanger.
4Measure the hole. Cut a piece of new sheet steel to lay in the hole and rest on the flange.
5Connect the welder ground clamp to the chassis of the car. Use the spot welding gun to spot weld every 1 1/2-inch around the perimeter of the patch.
6Prime and paint the finished repair, both inside and out.
