Carrying on with the weldathon that is my Puma. I had a look under the front bulkhead and it looked a little rusty but I thought it might clean up,
Inside the car there looked to be a little surface rust on the seam.
So I attacked the underside of the seam and ended up with this. The bulkhead looks salvageable but it looks like I'll have to cut another patch out of the floorpan
Same as usual I marked out the limit of cut by drilling through from underneath and marked out the line of cut above using masking tape
Cut from above, unfortunately there is a little rot on the top face of the bulkhead so this will have to be cut out as well
View from below.
I cut out the patch from the bulkhead and also extended the hole in the floor and then cut out the patches ready for welding.
View from below
It's important when welding in patches to have them at the same height as the surrounding metal so I used a bodywork dolly on a scissor jack to press the patch against to ensure the area remained level.
1st patch welded in.
2nd patch welded in.
View from underneath.
After etch primer and stonechip.
Ready for joint sealer.
Looking at the inner sill on the drivers side I could see rust breaking through the seam sealant
A quick rub with the drill ended up as this.
View from below before cleaning up
View from below after cleaning up
I'm not going to bother to inlay a patch to this as it's too fiddly so I will overlay and weld a small patch on top of this and finish it off from below.
Cleaned off and patch ready to go.
Patch welded in.
View from underneath.
Etch primered and stonechipped
Drivers side floor finished now at last!
Just these two patches left on the passenger side
Patches sized to fit and cut for spot welding.
Yay! Last patches (hopefully) welded in now!