My elderly Range Rover has grown holes in both front footwells.
That in the nearside is actually a series of perforations over about an A5 sized area. I can't get to the underside because of the outrigger just aft of the A post. I also doubt that I can clean off all of the underseal. I also do not want to cut the entire rotten area out because I'm sure that I can't slip the repair plate into place in such a way that there are no water traps - especially considering the access problem.
What I propose doing is MIG welding a plate over the entire area and onto sound metal on the inside - producing a rust trap that some car manufacturers would be proud off - and then filling the void between the new plate and existing (holely) floor with filler foam followed by underseal.
Any thoughts/suggestions would be welcome.
Richard