Since I had the driver's seat and steering wheel removed to access the brake booster mounts easily, I also decided to POR-15 the driver's floorpan.

I went to check out the passenger side, pulled the mat, and -- to my horror -- discovered not just small holes s but major elements rusting away. Egads!

That is totally open almost all the way across!

I was going to fiberglass it, but then remembered Wolf Steel in Quebec. US$80 and I have a new floorpan. Is this the best approach? Should I do something else?

With thanks and cheers,
phaetn

Welding a new steel floorpan is without any doubt a better solution than fiberglass.

Welding in new steel is clearly stronger. I think it depends on how extensive the rust is. If it's just limited to that area, I would probably either get a smaller steel patch and weld it in or (my favorite) pop rivet the patch in with some structural adhesive.
Kirk

It its only that area, I would get a smaller piece of metal, bend and weld. Personally not a big fan of the adhesive and pop rivet approach from a restoration standpoint but it works well particularly if you don't have access to a welder

That looks like it would need to be cut out and a patch welded in for a proper repair. With that be said, a quick repair would be POR-15 and fiberglass cloth. I had a '86 BMW that had a few bad places (nonstructural) that were repaired in 2011 and they have not needed any additional repair. The following link will show one of those repairs. I would use this approach on both sides of the floor.

http://www.r3vlimited.com/board/showthread.php?t=206642

I would get underneath and really look things over at this point.

Odds are there are other spots that need attention too.

I dunno, phaetn. When I bought my 72, I had the same issue on the driver's side, and could see the left front tire. Wolf Steel's floor pan, welded in by a friend who restores cars, has given me far more piece of mind than any other method. Might want to eyeball the seat supports while you're in there. Mine were on their way out, so new ones from Wolf got added to the project. Wolf has good stuff, and no shipping issues for you since they are in Canada!

Neil

Thanks for the reply, folks.

I've ordered the floorpan. US$90.40 with taxes and shipping included.

I know a crazy very salty old welder who really knows his stuff but is cheap. His "shop" still has an open pit since he's been in business for probably 45 years, and it was his father's before his. I might go get an extra panel from a local metal supply shop in case he needs extra, especially for the lip above the floor pan.

There was fibreglass on the driver's side under the pedals but it doesn't seem to give or flex. That might be a project for another year as I have POR-15ed the rest.

Seat rails look really good on both sides. It's where water spits up from the tires that looks the worse for wear.

Kmoses, thanks for the pics of the BMW repair. That's a great idea to use the POR-15 instead of resin on the cloth. I might use that tip elsewhere when the time comes.

Thanks and cheers,
phaetn