Bootwell rust repair

[s class]

Nice K-jet 280SE, with rust in the bootwells - aka the standard W116 / W123 issue.

The intent was to replace the horizontal floor pieces.  The right hand side was by far the worst, so I started there.  I cut out the rusted floor piece, and started cleaning up the surrounding areas to receive the new metal :





By this stage I was getting uncomfortable about the number of patches required.

Some further digging and inspection revealed this :

[s class]

after lunch this was the next step :



Sweaty palms, drum rolls, and all that :

[s class]

Some priceless pieces from a rust-free donor :







Tomorrow will be trimming back the section piece for proper alignment, and butt welding. 

[Squiggle Dog]

I like seeing the process of repairs like this.

[oversize]

Nice job so far; well done!

[robertd]

You need nerves of steel to cut into a car like that.
But the result will be worth it.
Rob

[WGB]

Looks great Ryan.
Thanks for sharing it with us.

Bill

[gf]

wow! this is great to see DIY cutting and welding. Its amazing how quick the arse end of these cars rots out if there is a leak. checked mine when i first bought it- all rust free. 6 months later noticed the carpets were damp and a lot of rust! all fixed now.

[oversize]

So how did you cut the donor panel along the same line and how do you intend to weld it on?

[s class]

Cutting was done with careful measurements, and then I cut slightly oversize.  Lots of test fitting and trimming until the fit is perfect. 

I will be welding with MIG (CO2/Argon blend). 

[oversize]

Sounds good!  Obviously the idea would be to tack-weld it in place before final welding.  I've heard of stitch welding and was wondering what that's all about; particularly what's the advantages?

[s class]

Donor panel aligned and tacked in place :





And from the inside :



Seam welded :

[TJ 450]

Nice work there, S Class.

It inspires me for next weekend's rust repairs on my 280S that I've been quietly working on.

Tim

[oversize]

WOW that looks so good!  Great job; wonderful in fact!!  WAY better than just covering the rust with body filler....  With the amount of work to hide filler, you'd be better off doing it right way and not worrying about it coming back!

[gf]

Cool! you make it look so easy! just like lego!
You should have seen my attempts at welding (not on a car thank god)