I had the patch panel for the holes in the floor sat in the back of the car, so I decided to make a start on it today. Out of curiosity, I tested the pin holes that I’d found when I was cleaning the footwell originally to see how badly gone they were. Using a broken screwdriver as a punch. I hammered them through. They bent rather than shattered, and the sorrounding area did as well. It looks like the majority of the metal is rock solid, but it’s hard to tell with the brown paint and surface rust.

I hammered a chisel across the holes to split the metal, and sure enough it was clean, silver metal within a centimetre or so. The surface was badly pitted, but it was solid. At this point I was in two minds about patching it or replacing it. In the end I thought “Might as well” and carried on chiseling. A few hours later I had the majority of it out and was knackered. Felt better though as I’d done it by hand.

I covered the screen and side windows with thick cardboard and taped up the joins the next day (Sunday) so I could finish the edges with the grinder. The support for the pillar sandwiches the floor to a support underneath, and after looking at it for ages decided to drill the spot welds and split that away and fit the floor properly.
More chiseling and the support was out. I was concerned that the weight of the body would twist it while it was missing the supports. I couldn’t see any movement, but to be on the safe side I left a lip of the original metal and folded it over in the corner under the pillar as a support. The edges were cleaned up with the grinder, and the bolt holding the very tired body mounting rubber removed..

It was getting late so after checking and double checking, I clamped it as best I could and put a few tacks round the edges. It’ll keep it from moving till I get some decent clamps and a better mask so I dont blind myself trying to hold the metal down as I weld.