When doing work on floor boards, you have to make sure no water can get into the cabin! This goes doubly if the car will be outside at any point.
First, identify the rust holes. Then mark them with a marker or welder’s chalk. And then get to cutting!
This is also a review on the Dremel 4000, and how poor the cutting discs are, that eat up fast or disintegrate. The quality is beyond poor, rendering it borderline useless to anyone that needs to get any work done.
Corners are the biggest issue when cutting, and while the angle grinder does a great job, it has trouble fitting in corners.
Keep in mind to always put the angle grinder on for safety.
I still have to try with the Dremel though, but it continuously fails, discs biting the dust over and over, twenty in total!
In the end, if comes down to using a hammer and chisel, and my new favorite, the Vampliers extractor pliers!
Just keep in mind, that you should always know what is underneath the cutting area. Inspect as best you can, crawl under the car, get a camera under, do what you can! You don’t want to cut the frame or chassis. Also, you can better see the rust holes from below as light reveals them.
Did I mention the Vampliers? They are outstanding at doing their job, as well as other jobs they werent meant for.
You should try to remove rusted sheetmetal in one piece, so you can trace the outline onto the new metal, but in many cases the metal may be too rusted, or simple impossible. Here, the sheet metal is welded from below, and thus cannot come out in one piece. Yes, its more work, but such is life.
As you remove pieces, stop and inspect where any holes are, where water can come in. While you do this, revise your plan. Think more than just one step ahead.
Going back to cutting, you can use metal fatigue to tear pieces off, jerking in back and forth with break each piece off, and having a good set of pliers makes this part a lot easier.
Tin snips are also good, but I found they don’t do well at cutting in weird corners, but they can cut tabs that can be broken off with the pliers.
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