The edge of the floor pan along the entire passenger side rusted through. I made some patches and welded it all up. Everything is butt welded. I didn't take the time to metal finish the seams as they are not visible.

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You're getting good at this!

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Thanks! Here are some more views.

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And more:

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Now who was it who was saying a while back he'd had enough of making custom panels?

How are you making them?

Have you got a thread on metalmeet going? (I haven't been over there for quite a while)

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

You remembered that I vowed not to make them! In this case, I don't think the footwell panel is available but I didn't research it extensively. The other floor pan pieces were fairly straightforward to make so it wasn't worth buying the whole floor pan just for the narrow strips that I needed.

In the case of the footwell piece, I used tuck shrinking to gather the metal around the bend. I didn't start a thread on metal meet or anything as I didn't consider it exciting enough!

How about you? Did you put your car back together yet!

Here's anither piece for your metal enjoyment:

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And from the underside:

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And the footwell piece I made, before installation:

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Have you got shrinking / stretch jaws?

(This isn't a question about someone's physical attributes!)

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

I do actually, but the bend was too much for the shrinker stretcher alone. I did most of it by tuck shrinking but used the shrinker as well.

My hero!

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Haha, it just takes patience and persistence. That floor pan repair took many full days and I'm still not anywhere near done- the rocker panel around the jack point is all rotted! Clearly this a labor of love!

And it sounds like you're going to have a genuinely rust free Mercedes in Boston. I guess that's about as rare as rocking horse ****.

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!