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BE Spring bos condition

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I'm in the process of doing the same thing you're facing right now. My car didn't look as bad as yours and I stripped it down to the tub and put it on a rotisserie. I found as I attempted to cut back the rust and replace sections of the damage, that the damage went much further than I could see from the outside. Also, you can't just weld these 19gauge replacement panels to any of that original metal that has any rust on it. The arc even from a quality shielded gas mig welder will be very erratic and produce weak, ineffective welds that won't do you much good in a high stress area like that. I can see from your pictures that most of the floor under that aft spring box area is going to have to come out. that will require you to remove the transmission tunnel floor brace (carefully because this part isn't available). You might be able to use one of those half shut plate repair panels if you can get the old section off and the spring box under it isn't damaged too much. If not you'll have to remove the shock mount braces and cut the whole thing out, locate the proper mounting locations for new spring boxes onto a new shut plate. Have you put any thought into how you want to repair the damaged inner fender where it meets the shut plate? that thing is completely rotted away. How about the inner rocker panel where the shut plate attaches? There has to be a good solid atachment there. All these pieces are made of relatively thin material that when properly joined form a strong structure. but only when all pieces are tightley joined and properly welded. the last thing you want is to get this thing on the road and have the welds start shearing off. Sorry if I sound like a pessimistic know it all, but I see you embarking on the same journey that I started a year and a half ago, and have encountered one demorilizing mess after another! Here's a link to my project. Hope it helps, or that I can be of help in any other way.
Regards
Mark
https://www.spritespot.com/gallery/view_album.php?set_albumName=1960-bugeye-refurb
 
Update: got some time the other day so I have removed the bad section of passenger side floor, I was able to swing bottom spring plate down to release old floor Hopefully I won't have any issues when putting back together


 


Didn't have metal for floor so I started patching holes, this is where someone install 3rd stop light. and hole to left is for power antenna that will not be used

........

placed copper under it then bridged it in small hole, the big hole I placed a plug



 
Last night on the way home I purchase 4 new stainless steel bolts from the tractor supply to bolt the spring plate and new floor strenghtener together. I now have completed the floor/spring box repair on passenger side.

Thank goodness this is just a driver since it will never pass for stock since I hand made all my panels from stock useing hammers for shaping. I will move to the other side but first I need to patch fender at door and install new sill on drivers side.

I actually tried to make this area stronger, by using heavier metal and larger overlaps. Once I have done the other side I am going to rhino line complete floor area so this will help with appearance of my handy work.
 
Someone told me they had the #17 #18 Endcaps for the passenger side outer sill, I lost the message, I am ready to buy if you see this PM me, also anyone have the left of right outer sill and want to sell.PM me Thanks
 
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