Ford Ranger: Day 9 Finished, Driver side Floor pan patch repair! Final red paint top coat "

Ablecraft's 1998 Ford Ranger driver side floor pan is being repaired with a metal patch welded in after the rusted floor pan metal is removed. I'm looking over the extent of the rust on the floor pan to see what the overall scope of the floor pan repair is going to entail.

Day1: I'm cutting 3/16th sheet metal on a lift cart to fabricate a floor pan patch. The floor pan needs to be ridge it to prevent flex when my feet are resting on it while driving. A vice too brace the metal patch along with a hammer and block allows the metal to be indented to form a bead.

Day 2: I'm using a 4.5 angle grinder with a grinding disc to remove the accumulation of rust on the floor pan. The reason why this is being done is determine where I'm going to lay my metal patch for the eventual cut and but with lap welding.

Day 3: Today the metal patch is spot welded in place over the rusted hole. Then I'll use an angle grinder and cut along each welded area and the rusted metal will fall out. The new patch will fall into place to be butt welded in.

Day 4: The fabrication of an extension metal patch to be welded was made. I find it easier at times to fabricate metal patches in sections instead of one whole piece. The reason being i may have to take into consideration an angle cut with a challenging dimension to measure.

Day 5: Applying Rust- oleum automotive filler primer to the topside and underside of metal patch. A total of four coats sprayed on both sides with a 10-minute wait time between coats.

Day 6: Evercoat automotive seam sealer was applied to weld seams. Three coats of Rust-oleum International Harvester Red aerosol spray paint sprayed on underside of metal patch repair.

Day 7: Final underside view of patch repair.

Day 8: The caulking gun applied the Evercoat automotive seam sealer to welds efficiently. A metal spoon spread smoothed the seam sealer in the concurs of the patch.

Day 9: 4 coats of International Harvester Red was sprayed on the patch repair to finish the floor pan patch repair.

Tools and supplies:
Titanium Easy 125 Flux Core Welder
.030 Vulcan flux core wire. (Welder settings B/C Voltage, 2 Wire speed)
Welding gloves
Welding hood
Maddox 7-piece autobody shop dolly set
Hercules brand 40 grit, 220 grit, 500 grit sandpaper.
Hercules brand 40 grit grinding wheel
Vise
C clamps
500 lb table lift cart
Respirator
dust nose face mask
2 cans Rust-oleum automotive primer aerosol spray paint
1 can Rust-oleum International Harvester Red aerosol spray paint
wire brush
3/16 Sheet metal