Cars structure after cutting out floor

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PostPosted: Wed Feb 08, 2023 8:59 am
Hello everyone! I have a 1983 190d which has rusted alot. I have to cut the rusted parts of the floor to weld in new fresh metal. Is the cars structure affected badly ? Can i just take a sheet of metal, cut it to size and weld back in? I have attached the picture of the big hole in the floor. Thanks for helping!
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PostPosted: Thu Feb 09, 2023 8:09 am
Not sure what a 190D is, but if it's unibody, the chances that it may affect structure, is higher. While some people just weld in a sheet of metal, it's not the better way. You see all those ribs, and designs in the other panels? they are not there for decoration, they are there to strengthen the thin metal. If replacing panels that have them, it would be best to duplicate these ribs, as best you can. If not, at least use a bead roller to put strengthening ribs in the panels, so they won't oil can when weight is put on them. Use 18 ga. steel for the repair, 16 if you want to give some extra stiffness.



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PostPosted: Thu Feb 09, 2023 8:29 am
chopolds wrote:Not sure what a 190D is, but if it's unibody, the chances that it may affect structure, is higher. While some people just weld in a sheet of metal, it's not the better way. You see all those ribs, and designs in the other panels? they are not there for decoration, they are there to strengthen the thin metal. If replacing panels that have them, it would be best to duplicate these ribs, as best you can. If not, at least use a bead roller to put strengthening ribs in the panels, so they won't oil can when weight is put on them. Use 18 ga. steel for the repair, 16 if you want to give some extra stiffness.


:goodpost:

I would add that Rust goes further than your marks you have marked.
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Thu Feb 09, 2023 10:20 am
Thanks for helping. I will try to recreate the original pattern as much as possible. I will also use thicker metal than the original, so it will hold better. And those markings were not final, if its needed i will cut till the metal is good. I also plan to protect the whole underbody of the car, so future rust shouldn't be a problem. The car was very cheap, and it's so rough that it doesn't have to be perfect. I am basicaly saving the car from going to a junkyard. Thanks again!



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PostPosted: Thu Feb 09, 2023 11:31 am
190d is a mercedes model from the 80's
The petrol engine cars were 190e.



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PostPosted: Sat Feb 11, 2023 9:12 am
The 190 D is a Diesel if I am not mistaken ?
They have a strong following

I would not use thicker material for the repairs.
Being able to replicate the original shapes groves and channels in the floor along with its original shape will be tough, requiring some expensive special equipment. It can all be done by Hand But would require skills I have yet to master. It would be much faster and easier if you could locate a replacement floor new or used?
Just out of curiosity How is the rest of the Body? When rust has gone this far usually the Quarters are gone as well as Trunk and Fire wall not to mention everything in between.

Can you get some better pics of the inner wheel well were it meets the floor and the rear seat bulk head? Both sides appear very rusty going deeper into the Rocker panel area on both sides and further up the sides reaching almost the top of the seat bulk head.
It would also be a good idea to see the metal in these areas from the underside.
I am looking at the one pic and wondering how far its gonna take to get to good metal to weld too? The rust in this pic is extensive!
I am not their BUT too me it looks like it may be too far gone to repair and save this car economically proper repairs will easily exceeds the cars current replacement value, It may be a better parts car for another car?

Similar situation happened to me with My Plymouth project, I was neck deep into it and it too was riddled with Rust I ended up buying a Parts car to cut up for rust repair panels to repair my car after I got the parts car home and really started looking at it closely it didn't take me long to make the decision to switch gears to restore the parts car using parts from my car. Don't get sentimental to a piece of metal were literally tens of thousands were produced where one chassis is the same to another only requiring a little paint to be what one had before.

The point being Know when to say "This one is just too far Gone to save" BUT only you can say! I have seen cars in far worse shape fully restored from a lot less but the return was far more.
Far to many get caught up with sentimental value for a piece of metal were tens of thousands were produced. In many cases its far cheaper to repaint another car to have a copy of a car one once had.
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.

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