Hi all, so I recently picked up a 98 EJ6 Hatch shell on an amazing deal if i do say so that will receive all needed components to make it a drive-able vehicle from my wrecked 99 coupe. Of all the small issues with the vehicle there was only one i felt could be of any real concern and thats this





I have no idea why someone thought this was a good idea....

Anyways fortunately there is very little to any rust in this cuts yet but I do live in a region with 4 seasons and would prefer to not have my car rust away in the middle due to these stupid cuts or worse in the event of an accident have the floor pan totally fail. I've been looking around for ideas to fix this and only really 2 have come to mind...the first would be to totally cut out the door sills and replace with door sills from the coupe and re weld them back in...this seems like a crap shoot though because it wouldn't be professionally done and could make things worse.
My 2nd idea is to leave the cuts and cover them with the door sill panels so they're not immediately visible but Fill in the chassis rails with expanding foam so that empty pocket is reinforced and safer.....I dont mind taking a 20 pound weight penalty for the piece of mind this would provide...also I know the idea has merit since its is done to race prepped chassis to help stiffen the rigidity of the vehicle.

Well if anyone has any helpful advice to chime in that would be awesome.

 

Hello anybody? anyone have an idea?

 

I have no experience in this, but if it was me I would weld or something sheet metal over the cuts and just make sure to paint it, so the ruSt doesn't come.
Everything is engineered to work and crush in the certain place a certain way, I'm not sure how the foam would affect that.

 

don't use ond it will crack, if you have the time and patience get sheet metal and draw out hole the exact same size on the door and get someone you know to weld them and spray it with primer (the one that stops rust from spreading) i had to go through this because one of my friend's integra had holes cut out for a spoiler, hopes this helps

 

Oh you can also try fiberglassing it

 

or go to a jukyard cut out a peice and weld it on

 

just get the door trim. it will cover it.
that foam crap that sounds like such a good idea all the time traps water against the metal....rust gets worse

 

That needs to be welded. Same gauge sheetmetal, you gotta fit it good enough and then tack weld them all in, once it's all tacked in it'll need to be fully welded. That'd bring back any structural rigidity that may have been lost.

 

yeah I think ill just chop the coupe thats junkyard bound to supply the replacement metal

 

Get whatever sized hole saw was used to cut those holes, cut out another set in the same gauge sheetmetal and weld them in, grind the welds flat and then epoxy and paint the area.

Do not use foam, it will just make everything rust twice as fast.

 

Best answer in the thread! I was gonna say use a rust repair panel from Mill Supply Inc. but they only make rockers/door sills for a 4 door.