Welding patches to repair rust

2001 Jimny

There are two areas of rust in the floor of my Jimny that the MOT tester brought to my attention but passed it anyway. So I thought it best to fix them before the next test.

The attached photos show the areas arrowed - next to the front subframe mounting and at the front of the sill.

Subframe: to avoid having remove the mounting, can this area be accessed and a patch welded inside the car by removing the carpet?

Sill: the rust is behind and beside what I presume is a stiffening bracket that I shall have to cut off to patch the rust. Can I get away with not making a new stiffener here?

Thanks in advance for the benefit of your combined experience with rusty Jimnys!

subframe.No access from inside unless you cut the floor out above
sill.Just cut the rust out weld the floor up first then rebuild the strengthener

After all the welding is finished, it is of paramount importance to perform the following:
1. Apply an epoxy based primer paint over the bare metal, including the welds;
2. Seal all the welds with a polyurethane seam sealer compound;
3. Apply a non-porous finishing coating of your choice (paint, bitumen, etc.) over the primer paint and over the sealant;
4. Apply wax over layer #3.

Seam sealing compounds are usually available in tubes for uses in a calking gun.


It would be ideal if all the above could be applied from both sides of the welded sheet.