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Ok i know ALL of us have had this problem, on the passenger side floor pan of my 79, I have a spot rusting through, some small holes have already appeared and the surrounding metal is a little weak. What is the best material to replace the section I cut out and is there any good undercoating or even bedliner on the market for me?
For matching purposes get a replacement floor pan and just cut out what you need, but really any piece of sheet metal will work and you can just form it to fit. It's just a matter of what you want to spend and if you care about looks underneath. Either way, I'd put some seam sealer on after you repaired the hole. I personally would use a good rust prevent paint like Rust Bullet, but others have used brush on undercoating like Herculiner. I've never used those DIY undercoating so I can't say how they will hold up. IF anything, paint the patch after you seam sealed it than if you want to use an undercoating, scuff the surface and then brush on the undercoat. At least if the coating does flake off in a spot, you'll still have the paint to prevent rust.
If you really want a good treatment and willing to spend a bit more money, have the inside of the floor rhino lined or Line X'd. YOu'll still have to coat the bottom side, but if you plan on having carpet inside at least the top side will be coated well. Carpet, rubber mats and moisture are what kills these floor pans.
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