1990 240DL

Note to self: do not work on vehicle when tired, extremely irritated and in a hurry!

Okay, so in attempting to tip the car to overfill the transmission, I made a really DUMB mistake. I knew I wanted to leave the jack point immediately behind the front driver's wheel open for a jack stand, so, while being in a hurry to get this project done after just discovering the mechanic had not tightened the gland nuts before aligning it, I looked for a close second point.

My old Ram50 pickup (framed vehicle) had a round jack point that looked like the little round point behind the jack point on Junior (unibody vehicle). Cool! This will be really quick! Dumb, dumB, duMB, dUMB, DUMB!!!!

Unfortunately, by the time I figured out it didn't feel right, I had already split the floor pan seam. There is now a wedge gap that goes from 3/4" to 0" in the front part of the seam.

Fortunately, the opening is toward the back of the vehicle, so road slush won't be thrown directly in off the tires. However, how do I fill/weatherproof it so I'm not dealing with super-premature floor pan rot/rocker panel rot? I've already lost my '86 244 to the rocker panel rust monster, and would prefer to not repeat the experience.

Having no body work experience yet, the only thing I could think of was the foam crack filler (Great Stuff?), but I wasn't sure if that would be a good enough seal, or if the air pockets would trap corrosive materials as well, and make it worse.

Any suggestions would be greatly appreciated!

I think I can, I think I can, I think I can get Junior on the road!

--
'84 244, Peter, never drove. Robbed to fix Paul, '86 244 - drove for 2 years; holey saint now, passing parts to Paul Jr, '90 244, yet to drive. Friends w/ '90 245, jokingly aka Mary, (pregnant sedan & completes PPM trilogy). Daughter to unnamed '90 745.