September rolled around, the car has been on jackstands for a year, and I knew if I didn't get the rust repair finished, I'd never get this car back together.
So what do you do when you have no welding experience and have lots of questions? Post to the forum!
Lots of good advice here and some inspiration pictures from other members:
Armed with knowledge, time to get this rustball rolling.
Here's what I started with:
The floorpan had been "patched" by a previous owner very poorly, I ripped that out. The frame extension was completely rotted, the lower inner rocker was rotted, and the the area below the pedal box was completely gone.
Removing the old rotted areas:
Fabbing a new inner rocker patch from 16 gauge steel:
Lower firewall/below pedal box:
Mocked up, using the pedal box to help locate it:
Welded in + the frame rail extension in place:
W&N floor pan welded in, I did screw up and left too big a gap at the rear. I ended up filling it with weld with the help of a magnetic copper backer
Seam sealer over the welds and gaps, and then covered in leftover rustoleum from the engine bay:
Cleaned the entire wheel well and then coated it with Rustoleum undercoating: