The passenger front floor pan was completely rusted out and the floor pan area was removed.
A donor passenger and driver front floor pans were cut from another vehicle found in a automotive salvage yard using a electric saws-all. The spot welds that held the floor sheet metal to the uni-body frame rail were drilled out using a spot weld bit remover.
It was necessary to fabricate a new flange piece (2 sections for ease of build) to be spot welded to the passenger side inner frame rail, so that the donor floor pan could be attached to create the new floor.
The remaining surrounding floor area was temporarily trimmed to fit the donor floor pan.
The new donor floor pan will require some patch pieces to complete the floor. For the patch pieces, I used the excess sheet metal that were trimmed off of the donor floor pans. Once the patch piece is tack in, the welds are ground down with an air disc grinder.