W114 / W115 rust repair (journey with pictures) -PART IX
by Patryk Rebisz

1. Now that the corner is secure, I can move on to cutting out more rust—most of which was caused by the previous poor repair: (Tip: Don’t overlap more than 3/4 of an inch, or moisture will collect and, with no way to escape, will rust out your repair.)

2. The inner rocker was completely rusted out underneath, so I cut it out:

3. I then fabricated a new one from a flat piece of metal (much easier to write than to actually do!):

4. Next, I cut out the remaining rusty floor (including the seat mount) and welded in the top rocker patch. It’s not the prettiest, but the seams will be covered with seam sealer—and the whole thing will be hidden under carpet anyway:

5. I started fabricating the floor replacement:

6. The new floors are welded in:

7. And finally, everything is painted. I still need to seam-seal the edges and welds, and install the seat bracket:

Part X in the next post.