We've Got Ourselves a Rust Hole!

Actually, we have a lot of rust holes. But since we're eating this elephant one bite at a time, Steve has started to work on this particular hole that should be repaired before we put the new heater channel in.

This rust hole goes through three thicknesses of the car.



Here Steve is cutting out the rusty part...only cutting out that part of the layer that needed to be replaced.



Then he made templates out of cardboard, just like Chad suggested in the Bug Me Video. He made three templates, one for each layer of repair. This is the top template.



Then he cut and trimmed each piece, till it fit snuggly into place. The sheet metal he used is part of what used to be the old floor pan, I believe...some of it was still in pretty good condition. Waste not, want not.





Here's what it looks like...



This is what it looks like from underneath the car...nice, huh??



Now he just wants to treat the area with a rust reformer, then he'll weld it into place and cover it with seam sealer.

Here's what he plans on tackling next!



It's good that we have lots to do indoors...this is what it looks like outside our shop!