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2018 Catchup #2 - Rust Repair

xr4tic

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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:

https://www.bmw2002faq.com/forums/topic/225875-floorpan-frame-rail-replacement-questions/

 

Armed with knowledge, time to get this rustball rolling.

 

Here's what I started with:

20180602_181353.thumb.jpg.79e3f2715e210a98b3849291bb2ae8c1.jpg

 

20180602_182020.thumb.jpg.06ce56dc46cf1ab411ac7b07e5dda191.jpg

 

20180803_194629.thumb.jpg.6bad0d1244a679d9cdd6fb6881fd6ad1.jpg

 

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:

20180807_201806.thumb.jpg.cc6b616bbd7b91cf58cb247886bf5781.jpg

 

20180808_180111.thumb.jpg.fcc94839aa2e30a7b8052a0eb227a8b9.jpg

 

Fabbing a new inner rocker patch from 16 gauge steel:

20181011_190055.thumb.jpg.9a05a321fccfe25c67797ca37bcf3d76.jpg

 

Welded in:

20181013_150912.thumb.jpg.1597b159720f6ba2ad730fe00925f88d.jpg

 

Lower firewall/below pedal box:

20181013_151956.thumb.jpg.3125fe1a4830052c9d6067b75122ddf8.jpg

 

Mocked up, using the pedal box to help locate it:

20181014_140826.thumb.jpg.da02b5be508a712e1a23b4e145b5be11.jpg

 

Welded in + the frame rail extension in place:

20181014_183141.thumb.jpg.d759113812d41b74f16632ba2b291404.jpg

 

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

20181019_140609.thumb.jpg.c526d4d45f3b757cc124c80b35e1268a.jpg

 

Seam sealer over the welds and gaps, and then covered in leftover rustoleum from the engine bay:

20181021_172648.thumb.jpg.3424e4928016734090e6a417e318d1c4.jpg

 

Cleaned the entire wheel well and then coated it with Rustoleum undercoating:

20181019_145723.thumb.jpg.a6fc9de23c6d70fcff48b4b9be630f60.jpg

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