Hey guys, I did a brief scan through this section but I definitely could have searched harder for an answer but I'd rather get a bunch of angry posts with a few helpful ones haha.

Currently cleaning up a shell of a 91 CRX Si and we want to fix the few rot holes in the floor boards.
Pretty much just looking for the best metal to use and any tips/tricks/problems that anyone has run into on welding these old floor boards.
Overlap the metal or cut to exact fit and weld?
I will not be the one personally welding, my friend has a mobile mig welder.

We have scraped away majority of the rust but we def are going to clean it up more before the actual patching. Debated between just metal riveting and sealing it or welding it.. and we figured we might as well just weld it.

This vehicle will not be a DD or driven in snow/heavy moisture so I'm not super concerned on having it perfect, just want it to look nice and pretty and not to have the rot spread. We will be spraying the interior metal with rhino liner or comparable.

First set of pictures are the passenger front:



This is the largest of all holes, right in the top left corner where the floorboard bends up to the firewall and center hump.


Simple square cut and square patch.

Simple rectangle cut and patch.


Next is the driver side, only one hole on this side:




Also a tough spot.

 

Having done these repairs myself, my best advice is to cut at least 1/2" more metal than you think you need to. Then build your patches and weld them in. apply seam sealer after and you're good to go for a few more years.