Assembly

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Repair floor pan rust
Cut out any rust in the floor, weld in a replacement floor pan, treat and remove all surface rust before seam sealing and topcoating with paint
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Plan
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Parts
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Gallery
Decisions & Unknowns
What I need to figure out:
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Lap or butt weld? Butt
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Best rust treatment for inside of frame rail?
Rust mitigation plan
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Minor surface rust:
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Wire wheel - Ospho - RAPTOR 2K epoxy everywhere → seam sealer → topcoat
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Pitting / inaccessible rust but solid sheet metal:
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prep → Rust Bullet → 72 hour cure → sand with 80–100 grit → RAPTOR epoxy → topcoat
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Holes or loss of structural integrity:
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Cut out panel - butt-weld in new steel - wire wheel/scuff - clean - Raptor 2K epoxy - 3M seam sealer - topcoat
Supplies
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Rust bullet paint
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Buttwelding panel clamps
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U-POL RAPTOR 4:1 Anti-Corrosive Epoxy Primer
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Wurth stonegard black Schutz kit
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Oil grease and wax remover
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Foam roller
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3M 08308 seam sealer
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200mL epoxy applicator
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Fertan cavity wax
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BMW jadegrun paint
Tasks
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Remove factory sound deadening to see extent of rust
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Fit replacement panel and trace outline
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Check below car
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Cut rusty metal out
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Grind and prep floor and frame rail
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Rust treatment inside frame rail
•
Minor surface rust:
•
Wire wheel - Ospho - RAPTOR 2K epoxy everywhere → seam sealer → topcoat
•
Pitting / inaccessible rust but solid sheet metal:
•
prep → Rust Bullet → 72 hour cure → sand with 80–100 grit → RAPTOR epoxy → topcoat
•
Holes or loss of structural integrity:
•
Cut out panel - butt-weld in new steel - wire wheel/scuff - clean - Raptor 2K epoxy - 3M seam sealer - topcoat
•
apply cavity wax inside frame rail and rockers