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2001 Civic Trunk Rust Repair 

My neighbor Lewi had water seeping into his trunk. He told me he had some work done on it recently at a local shop and but some water was still seeping in. Popped the trunk and had a look...

December 2014

Once popping the trunk open, I found a sheet metal tack welded on the trunk floor. (I haven't taken a picture of that unfortunately arghh..). Once I grinded the welds and took it off, I saw a big hole torn in the floor panel. Road water was going into the hole and seeping under the tack welded sheet metal. I decided to cut a rough square perimeter around the hole (visible above)

Once that was done, I took a shoe box cardboard, placed it under the trunk and picked it up using a screw through the square void I have just cut until it established contact with the lower trunk surface. Then I took a pen and traced the perimeter onto the cardboard.

I took the cardboard and cut along the traced perimeter precisely with a blade. Used a ruler as necessary.

Then I tool a sharpie and traced the perimeter off the cardboard onto a large sheet metal piece I had lying around. The perimeter had to be cut precisely so I used a jigsaw with a metal cutting blade.

Placed the cut piece on the square void and tack welded it into position. Then i seam welded along the entire perimeter.

Lewi insisted on a drain plug so I cut hole and placed a rubber plug. Rubber coated below and that was it. Lewi wasn't interested in priming/coating the welded sheet metal. Old car, not worth the investment he thought.