Here is the back side of the heater channel with a patch in place and a small patch welded in to cover a small rust hole. This area was cut out and I used more of the fender for donor metal. The welds will need to be dressed. Then I applied some primer and painted it with some gray enamel paint I had. I am planning to paint the car with enamel so there should not be incompatibility problems. After the paint dried I applied a good application of the seam sealer then I covered it with some more of the gray enamel to seal in the joints where the patches are. I am not concerned with the looks all that much because this area will get undercoated and you'll never really see the repair, unless you look for it.
Seam sealer is applied to the lower quarter panel seam. Note that I still place a piece of 4x4 post in where ever I am working. This will reduce the pinch points and serve as a back up support when the body is on the saw horses.
This shot is the welds all dressed and painted, sealed and repainted. I haven't put any undercoat on as that will happen after I get the car painted.
My small jack and big sander I call death with a hand grip. That thing is a monster and it loves to chew up metal with lots of sparks. Its heavy and has a lot of torque.
The heater channel bottom all welded and sealed and painted. I will sand the sill down a little and it will be painted the same color as the car, but I wanted to make sure it was sealed real good. I don't want any water getting in there and rusting it out again anytime soon.
Inside kick panel and A pillar. Notice how well everything is sealed and painted. I think that the A pillar repair turned out real nice! Carpet will cover the kick panel and the semi-noticeable fender well repair. The bulkhead will be the next section I work on and that is a another major surgery you wont want to miss!
Front fender well repair sealed and painted, although there is a small portion in the very front that needs finishing off. I will finish this when I do the bulkhead repair.
This is the rear part of the heater channel after the first couple coats of paint. I will apply seam sealer to the area then paint it again.
This is the area after the seam sealer was applied and several more coats of gray paint was sprayed on. This will seal out the water and moisture from the welds and the seams. I missed a spot under the heater duct which I will have to fix. I didn't notice it before so I will have to go back and redo it.
This is a shot of the front bottom plate and my re-engineering of the front bolts. Remember I said the nut plate was rusted away and the new channels didn't have a nut plate welded in place? Well this was my solution to the problem. I figured I would do it this way so all I would have to do it bust the nuts off if they get rusted on... like I going to take the body off when its done! You can also see that I haven't welded in the very front of the heater channel. I will cover this when I fix some rust in the front bulkhead. You also see my sloppiness with the seam sealer. A knife will take care of that. I will paint this area again and install the body to pan seal. The outside of the bottom plate will get some undercoat after the body is bolted back down. This will be to protect the paint on the bottom plate from rocks and road junk that gets kicked up from the tires.