I agree thats coming along great!

Just finish the right floor pan with new homemade rail support. I was naive to believe the left side is ok. There were no visible holes but when I removed the tar there was plenty rust. The master break cylinder was leaking so bad that if fill the break buster. At every break the fluid was coming inside, not much on the outside

Is amazing to find out that a car will rust from inside out. Not a single rust spot under the driver seat floor pan, original black finish, on the inside different story. When I spray rust inhibitor all turn black. Lucky me there is one small hole. do not drive a Fiat when is raining, do not store the fiat outside

lm48 wrote:Is amazing to find out that a car will rust from inside out. Not a single rust spot under the driver seat floor pan, original black finish, on the inside different story. When I spray rust inhibitor all turn black. Lucky me there is one small hole. do not drive a Fiat when is raining, do not store the fiat outside

Many years ago my neighbor showed me what interior carpet/pad does to the floorboards, complete and utter destruction of the metal. Luckily we now have good metal coatings that will prevent rust from taking over.

What is the copper plate used for? And how is it used?

Weld will not adhere to cupper, so if you drill a hole between to metal pieces you can use a 1/8" thick cupper on one side of the hole and fill in from other side with the welder. The plug created will be very durable. If you weld side by side two metal pieces of metal you hold the copper plate in the back and weld in the front. It work very good.

I am doing a complete pan and rail replacement. Pita! The trans, safety strap and shaft bearing mount bolts are right where the replacement pan meets with the tunnel. Any suggestions?

I see two options...
1- when you cut out the old floor, if the area around each driveline support bolt is in good shape, cut around them and trim the new pan to fit.
2-if the driveline support bolts are in questionable metal, bolt the appropriate support bracket in place, jig it from the bottom so it can't move and cut, grind everything away from the top of the bolt. One side at a time! Remove the bolt on that side and cut a plate with a hole drilled in it. Bolt this plate back the the support bracket and weld the plate to new and old all the way around.
Hope that helps...

I am having the same issue with the support bolts. I was going to do the same thing cutting around them and welding a new patch with a hole in it. Great advice.