Funky hole in the passenger floor. This had been patched sometime before I owned the car, with a piece of tin, some Great Stuff foam and undercoating. All cut out and replaced with new metal.
Heinous holes in the driver's floor. I didn't know about the one under the gas pedal until the other day; it was invisible from underneath but when they pulled out the carpet there was no metal left there, just the undercoat.
The gas pedal bracket was totally gone so they fabricated a new one to weld in.I had had the hole on the outside edge patched a couple years ago, and I thought the shop that did that work were competent but it ended up being just held in place with a bunch of screws and then covered up with undercoat.
They're working on filling these with new metal now, they're mostly done but haven't sent photos yet.
The right front fender initially looked good, but they found the bottom edge behind the wheel was pretty rotted. This could have been fixed, but it ended up being just as cheap to buy a whole new fender.
New fender goodness.
There was a bunch of other little rust spots that have been patched in, around door seams, in the rocker panels, the doglegs behind the passenger doors, around the taillights, some bubbles around the rear window. They've been fixed with new metal.
Finally, they're about done with the repair work and the fun stuff starts: In these photos there's several coats of wash primer (an acid etch that bites into metal for good adhesion between the metal and the epoxy sealer), 2 lights coats of epoxy sealer, and several coats of sanding primer.
Neat to see how it's actually repaired though!
