I’ll use some masking tape to section off the damaged parts, with attention to locate the spot welds and drains:
I may be able to save some of this outer rocker panel piece, but not what I find under it:
Now I have scuffed off the worst of the rust scale. I find what seems to be a good place to cut away the bottom of the B pillar:
This WAS 16 gauge steel:
So was this - the mid rocker:
Notice here the mid rocker is made in sections. I did not know this, and just happened to uncover a place where the lap weld is. Good to see the rust is only behind the B pillar.
This is the floor pan, just under and forward of where I am working. I spotted this damage earlier, and painted around it, knowing I would have to cut it out:
Cutting this away reveals the flange of the inner rocker rusted away too. I had to cut this out a little bit beyond what can be seen in this picture, to get back to solid metal.
I made a repair piece and welded it in, but did not get a picture of it.
Next to weld in a piece of 22 gauge to fill in the floor pan here.
Now I have all the rust cut out, and some of the pieces replaced. I mask the edges where I know I have more welding to do. Then I spray zinc primer inside, as I will not be able to it after this next patch:
This patch of 16 gauge steel was not too hard to make:
Next episode; I’ll make the B pillar structural repair, and start on some of the more cosmetic bits. Stay tuned.