Last time I was out to work on my car, I brought a piece of the rear seat bulkhead to repair.

As you can see, the bottom edge was totally rotten.  YUCK!  While most of the bottom inch is going to get cut off, there is a few inches of solid metal I wanted to preserve.  On the pic below, you can see the top right.  I need to remove the old floor metal that has been spot welded on to the flange.

In the next pic you can see where I have wire wheeled the flange and found the spot welds.  I've also ground down the metal around the spot welds for easy removal.

Next I grabbed on to the remaining bit of floor with a pair of vise-grips and peeled it away from the flange.  You can see the nubs of metal left here (and also where I have ground two of the nubs flush.)

Take some measurements.  Scribe some lines.  get ready to start cutting out the cancer.

Bend up a new flange out of some 22 gauge steel.  I thought I had some 18, but this will work. Clamp it tight to the panel so I can scribe my cut line on to it.

Wire wheel through the paint and rust.  Start welding.

The blow out was my initial tack weld, where I had my welder set to hot.  I really want to modify my welder to have infinite temperature variation rather then just the 4 positions it currently has.  

That's where I left off last night, as it was midnight and I did not want to piss off my neighbors by turning on my air grinder (and I was exhausted).

Welds need to be ground smooth and primed.  Hopefully the next time I get a work weekend on my car the rear floor will go in and I'll be able to weld in this piece of bulkhead.

But better to get this done now for homework, then waste time on a work weekend futzing with it.

Zach