While this car is very solid, it does have some rust issues. The right side jacking point had been damaged (never use the factory jack) and put a hole in the floors. That hole, combined with other water ingress over the years, made repairs necessary.

There was a lot of thin metal combined with pinholes, so we cut away the bad.

We had to cut back the middle crossmember and part of the floorboard after removing the footwell.

We made some tooling for our Pullmax and made a repair section for the floor.

We bent up a replacement crossmember on our sheet metal brake after making patterns of the original pieces in cardboard.

We butt welded the floor repair piece into place, then plug welded the footwell repair panel (sourced from SNG Barratt) in.

The completed repair is hard to distinguish from the existing bodywork.