So why haven't I sealed this yet? Been dragging my feet begrudgingly addressing the other areas that needed replaced. I used floorpan scraps for them. First this bit that holds the weather seal, both sides had some rust where the 2 ends come together. Driver's side was a bit worse. Once I cut back the seam sealer, how it went together became more clear.
Pretty tough not to blow through in a couple spots here. Next I finally admitted I was never going to be happy priming and sealing this seam on the passenger's side.
No amount of rust mort was going to get this satisfactory. Outside there was a downward facing sandwich of panels, all brown all the way through.
So I committed and threw myself into the fire. I did not butt weld the repair here as I was not about to replicate the seam I chopped out, but I did weld both ends of it.
The outside tolerated the heat really well and I just kept laying bead into the gaps until they were plugged. I thought this was odd seeing how I didn't blow through or anything. I got it when welding from the inside too, but my path from out to in was plugged as I did it last.
Had to remove the wheel and inner fender to gain access to both sides. Looks like that gets me good access to the inevitable broken exhaust manifold stud on the 454 as well. Too bad I'm not touching that this go around. I've opened Pandora's box wide enough as it is.
