1960 Audi Auto Union 1000S Floor Pan Restoration – Classic Car Welding & Restoration, Trowbridge

This gorgeous 1960 Audi Auto Union 1000S came into the workshop for rear floor pan repairs, and it's exactly the kind of job we love. Once the interior was stripped back, the full extent of the corrosion became clear - the original floor pan was badly rusted and well beyond a simple patch repair. Replacement panels simply don't exist for a car this age and this rare, so there was only one proper option: cut the rotten metal out completely and fabricate a new section entirely by hand, matching the original shape and strengthening ribs exactly. That meant careful measuring from what remained of the old panel before any metal was cut, then shaping and welding a new floor section from fresh steel to fit as though it had never been touched. Once the new panel was welded in, the repair was sealed and coated in a durable protective finish before the interior went back in. It's slow, time-consuming work compared to bolting in an off-the-shelf panel, but on a rare classic like this it's the only way to do the job properly and keep the car's originality intact for years of driving still to come.