How I finally fixed my rotten floor - steps that actually worked

Oct 16, 2026 Last reply: 1 day ago 4 Replies

First reply

syates

Did the rear footwell on my '73 Datsun pickup a couple summers back and your point about the rot spreading further than it looks hit home. What I thought was a hand-sized hole turned out to need nearly half the floor cut out once I got probing with a screwdriver. The dull thud…

Read the full reply

Been through this on my old coupe last winter and picked up a few things the hard way. Before you touch the grinder, poke around with a screwdriver and map out where the rot actually ends. It always goes further than it looks. I marked my cut lines with paint pen, staying well clear of the seat mounts and the crossmember, then cut the bad metal out in one piece so I coud use it as a template for the patch. Cut a couple of inches past where the rust visibly stops. Shiny looking metal can still be paper thin, so tap it with the hammer and listen. Dull thud means it goes.



For the patch itself, I made card templates first, then transferred to sheet and trimmed untill it dropped in with a small gap. Tack it in a few spots, check it sits level with the surrounding floor, then stitch between the tacks and let it cool between runs. Jumping around the seam keeps the panel from pulling out of shape. Seams got seam sealed top and bottom afterwards, then a coat of chassis paint before the carpet went back in.



One thing, keep a fire extinguisher or bucket of water nearby when grinding and welding. Underseal and old dirt smoulder way longer than you'd expect.


Did the rear footwell on my '73 Datsun pickup a couple summers back and your point about the rot spreading further than it looks hit home. What I thought was a hand-sized hole turned out to need nearly half the floor cut out once I got probing with a screwdriver. The dull thud trick works, though I also found pressing hard with the screwdriver tip whould punch through the thin spots that still looked okay from underneath.

One thing I'd add on the patch fitting: I cut my first panel dead flush to the hole and fought it for hours trying to get a tight seam. Second attempt I left a small gap and the tacks pulled everything in nice, way easier. Also ended up plugging the edges every inch or so instead of a continuous stitch on one section where the panel wanted to warp, and it stayed flatter doing it that way on thin sheet.

I skipped the card templates and just traced the old piece straight onto the new metal with a permanent marker, then trimmed with an angle grinder and a cutting disc. Took longer with the fitting but I don't own any fancy shears. definately on board with clearing everythingflammable out of the car first. I had sound deadening under the passenger side that started smouldering the day after I thought I was done cleaning up, smoked out the garage at 10pm. Now I let everything sit overnight with the windows cracked before calling it a day.

Back in the day we didn't always weld the patches in flush. On drivers and work trucks I used to lap the patch over good metal with a hammer and dolly flange, plug weld a few holes, seal the edge. Ugly if you flip the car over, but dead simple and strong. Fit was forgiving too since the overlap hides a sloppy cut. These days a buddy lends me his spot flanging pliers and it goes even quicker. Might be worth considering if the underside will never see a car show, saves a lot of fussing with gaps on thin metal.

Agree with the reply about lapping the patch over good metal, that's how I did the spare tire well on my old wagon and I'd never go back to butt welding on a floor. I flanged the edge over a short length of pipe clamped in the vise, then plug welded every couple inches and filled the low spots with body filler on the underside where nobody sees it. Fit was forgiving enough that I didn't even bother with card templates, just scribed around the old piece and trimmed with the grinder.

Update: tried the lap patch method on the passenger side since my butt welds kept blowing through thin spots. Way more forgiving, wish I'd done the whole floor that way. Still fighting the panel pulling down in the middle though, even jumping around the tacks. Do you guys clamp a brace across the opening while welding or am I just running too hot?

Join the Discussion

Have something to add? Share your thoughts — no account required.

Didn't find your answer?

Ask the community — no account required