Auto body repair & detailing: Mini Floor, aluminum rivets, rust holes

Question
I have a 79 Austin Mini with bad rust holes in the floor boards and wheel wells. I have found a place to pick up new body pieces and was wondering if welding is the only solution for replacement? I am not an avid welder and would have to take it to an autobody guy, but I heard their is a glue you can use. What would you suggest? Thank you. Ryan

Answer
Hello Ryan! You sound like you are from somewhere in the UK, so the materials that are available to me may likely not be available to you. There are structural adhesives available from a company called Norton, also from a company called SEM. I use products froma company called Kent, they have a line of repair products called Chem-weld. Try asking about adhesives at your nearest auto parts store that sells automotive refinish products. I personally like to first make the patches, and be sure they fit EXACTLY. Grind all paint and rust away, and cut away all rusty metal. Leave an inch overlap, about 23MM, to fasten the new patch to the body. Apply adhesive to the patch liberally. clamp the patch into position, or I like to use pop rivets in places where I can't put clamps. Then, coat over the seam with more adhesive, completely cover over any rivets. Use steel rivets, aluminum rivets will cause an electrolysis between the different metal types, leading to rust. Let dry 24 hours before removing the clamps. That's it! It's a bit pricey way to go, but easier than welding. I highly suspect it will last longer, also. The glue prevents water intrusion between the panels. good luck! Bill