Today planned project took a big turn for the worse. Upon removing the interior to clean it, found the front driver floor board rusted through. The bottom sub frame is still intact.
The rust is the thin top metal floor board, the gray in the image is the sub frame / frame rail.
Not sure what do at this point, floor pans are probably the worst thing to work on, odd shapes, double layered, hard to stop rust. Guess I will remove what I can, put the driver seat back in and take it in for an estimate.
If the estimate comes comes back high, might JB weld a piece on top of the floor pan. Although welding would be better, I know it would burn off the protective finish and create a bigger rust mess down the road
Removing the Interior Carpetinghttps://www.youtube.com/watch?v=mAVkr4WpqWU
Repair Video Part 1:https://www.youtube.com/watch?v=eIvwgptIJJ8
Repair Video Part 2:https://www.youtube.com/watch?v=Mu7a9SKYkZg
Thanks for all the feedback. After I had started the project, I found out their was an epoxy designed for this type of application, eliminating the need for rivets and some metal pre-painting. Link: http://www.nortonautomotive.com/636425-06420.aspx
Also, in this case, spilled sugary drinks caused most of the rust, traditional solvents would not remove the sugar. Had to use water with a little soap to get rid of the sugar, then clean the remaining adhesive and residue with traditional solvents.