Anyone think I could grind away as much as possible, treat the rust and then fiberglass the holes? Then I could spray the bottom with that rubberized under coating.
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O come on your losing weight that just means it will be faster. If your worried about the structure just put a full cage in it and call it good.

 

I might just set myself on fire with this one, but here it goes. Could you cut the metal that is completely rusted, then grid the metal that can be saved. Weld a piece of sheet metal to replaced the one you cut. Ive seen this on Horsepower TV, on spike. There have been many restorations in the show and that seems to be the solution for rusted panels.

 

Fab up a tube frame to hang your suspension from,the cut out the floor andhang the body on that.
-=G=-

 

I was just going to say this. +1

 

A new shell is cheaper, though, especially since you seem to have gotten into the recycling business, Phil. Just find a clean, red shell, swap your parts over, part out what you don't need. Ask Scott - I think he even ended up with some money in pocket.

 

In the scheme of things, I've seen my dad's shop save cars that had more rust than floorpan (very literally, you could see the ground under you) that make that work look like a cake walk.

It's fixable. What's easier for you?

 

Bah stop being a ***** and cut out that floorboard and jbweld some nice kick plate in.

 

Are floor pans available for our cars, or would I need to cut it out of a donor car?
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Couldn't you fabricate some sheet metal floor pieces? I'm not sure what would be harder: fabbing up some new floor pieces or transplanting all your parts to a new shell.

 

new floorpans is the easier option.

 

I'm starting to lean that way. I can get a floor pan out of a donor car no problem. Welding it into my car is the only hurdle.
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thats pretty much what I suggested. Any welding skills??

 

This is why I suggested tread plate and jbweld. And a hammer. It is under the carpet after all..

 

I wouldn't trust JB Weld for something that will see twist. Shitty welding will do better than JBW IMO.

 

I wouldnt get a whole new shell over that. I doubt it will affect rigidly noticeably. When I was restoring my 73 triumph gt6, both floor pans were completely toast. Just got some scrap sheet metal, made the appropriate bends/tapers, and welded them in really well while the car was on a level surface. Once the carpet was back in, nobody had a clue.

 

If you can mig a manifold for your turbo you can easily do this,Remember fit up is the key.
-=G=-

 

ok then liquid nails or silicone caulk.

 

My driverside floor is much worse then that, I would be very interested in replacement floorpans if someone is making them/going to make them.

 

You can buy them from Mazda. List is $220/side, but can be had for substantially cheaper.



I suppose you could also cut them off a tub that's smashed too badly to salvage.