The passenger side full length floor pan is basically in place. I still need to weld it to the rear torque box and finish welding the gaps left from cutting it. It’s also butt welded in place so that it looks a little cleaner from underneath. I tacked the new floor to the old leaving a bit of an overlap, then cut them both using a 3/64” cut off wheel so that the gap would be fairly close. It ended up making the gap between the old floor and the new floor a little too big though, so it’s difficult to weld all the gaps shut without blowing more holes in it, especially using flux core.
In the picture of the two pieces of the rear floor, you can see that the original metal is generally in better shape than the replaced metal. When the car was restored in the past, the floors were “replaced” by basically welding the new metal over the original, so everything is doubled up. I’m pretty sure they didn’t paint the new metal, or if they did, they didn’t do it very well.
Here’s the new floor mostly in place:
And here’s a patch on the passenger side inner rocker: