However, if you're determined to tackle it yourself, here's a general overview of the process. Remember safety first – wear appropriate safety gear including welding mask, gloves, and eye protection.
1. Assessment and Preparation:
* Extent of Damage: Thoroughly assess the extent of the damage. Is it just surface rust, a small hole, or significant rot? This determines the repair strategy. Small holes might be patched, larger areas will require replacement sections.
* Removal: You'll likely need to remove the carpet, seats, and possibly other interior components (like the console or seat belts) to access the damaged floorboard fully. Take pictures as you go to help with reassembly.
* Clean the Area: Remove all rust, loose metal, and debris from the damaged area using a wire brush, grinder, and/or sandblaster. This is crucial for a strong weld. Consider using a rust converter to treat any remaining rust.
2. Repair Options:
* Patching (Small Holes): For small holes, you can cut out the damaged section, creating a clean, square or rectangular opening. Fabricate a patch plate from a similar gauge metal (find a donor car or get sheet metal from a parts supplier). Weld the patch into place.
* Section Replacement (Large Holes/Extensive Damage): For larger holes or extensive rot, you'll need to cut out the damaged section and fabricate a replacement piece. This requires more advanced metalworking skills and often involves using a pattern to create the replacement.
* Using a Floorboard Patch Panel (If Available): Some suppliers might offer pre-made patch panels specifically designed for 1981 El Caminos. This simplifies the process, but you'll still need welding skills to install it.
3. Welding:
* Proper Welding Technique: You'll need a MIG welder for this job. Arc welding is possible but more challenging for sheet metal. Use proper welding techniques to avoid warping the metal. Multiple small welds are better than one large weld.
* Weld the Replacement: Carefully weld the patch or replacement section to the surrounding metal. Use clamps to hold it in place during welding.
4. Finishing:
* Grinding and Shaping: After welding, grind down the welds to smooth them out. Use a grinder with different grits of sanding discs to achieve a smooth surface.
* Body Filler (If Needed): Use body filler to fill any remaining imperfections or gaps. Sand smooth.
* Primer and Paint: Apply primer and then paint to match the existing floor color.
* Reassembly: Reinstall the carpet, seats, and other interior components.
Important Considerations:
* Undercoating: After repairs, apply undercoating to protect the floor from future rust.
* Seam Sealer: Use seam sealer to seal any gaps or joints between the new and old metal to prevent moisture from getting in.
* Safety: Welding produces sparks and fumes. Always wear appropriate safety equipment.
* Proper Ventilation: Work in a well-ventilated area.
This is a simplified overview. Repairing floorboards is complex, and there are many nuances depending on the specific damage. YouTube tutorials can be helpful for visualizing the process, but remember that each car is unique. Consider consulting a professional if you're uncertain about any aspect of the repair. A poorly executed repair can lead to safety issues and further damage down the road.
