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My 1990 240 was suffering from floor rot from the inside out due to a leak in the firewall. The rust had spread to the rear floorpan and from the drivers seat rear mount to the driveshaft tunnel. None of the body shops in town wanted to fool with a job like this so I decided to tackle it myself. I cut out all the rust out back to good metal, bought a MIG welder, and took the crash course "welding 240". In front of the driver seat, the rust had penetrated into the rocker panel underneath. I did not weld the hole up underneath for fear of causing more damage by not being able to properly seal and paint inside the rocker. My only other options would be to leave the hole open for water to drain, plug it up with seam sealer, or plug it with epoxy. What would you do?
Here is a photo of the finished repair. I forgot to take before shots, but the damage looked a lot like Dave Shannon's floor pan project shown on his site.
Here is the patched up hole in the front:
This is the underside of the patch showing the small hole in the rocker(thats not rust, it's just red primer):
Thanks,
Preston
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