Alright, I've learned that the welder is more of a feel thing. I'm using .035" solid wire because I though thicker wire would help penetration and lay down more material than the .025" I was using 16 gauge to patch and I was using the settings the welder recommended, but it just wasn't penetrating well enough, so I'm taking matters into my own hands. Higher heat-better penetration, as long as you're not blowing holes.

Now in the picture, I want to remove the front seat support (red) to ease the the patching of the hole underneath (green). I've been working on the hole circled in yellow. I also think the whole pan-rocker seam is infected, so I'm going to cut that whole thing out.

Does anyone know how difficult it is to take off the center console? And how bought that floor insulation? I'm really hoping someone has a good way to get that stuff up, cause it is busting my balls right now.

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition