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I removed the rugs that were in my car this weekend and honestly I was not going to post this because I had my own idea on what to do. The issue is that I have 3 spots that have rust. 2 of which are about 1.5-2in holes that exist. The other takes up a good percentage of the drivers side floor(pictures in this will show it all). As you can see in the picture, the surrounding area is also rusty, it looks a lot brighter in the picture, but still feels extremely strong. First instinct is to cut out the area that is rusted through weld in a panel(does it have to be grooved?) and POR the rest including the new panel. Second thought was to try the POR/Fiberglass patch idea, POR then Lay down a mat then POR again, but I am unsettled on that one because I keep hearing a voice in my head saying that isn't the right way to do it. I kind of want it done.
I would go with replacing the entire panel if replacements existed, 41 Buick not a popular enough car to make reproductions on. Making an entire panel myself is possible, but overly concerned about the time it will take to work it all out. Exactly what other options do I have.

BTW I did search the faq section on this and there are some articles, but the fact it is something that I cannot readily lay my hands on leads me here.

The small holes can easily be taken care of either by welding a small patch in or por puddy. I am less worried about that, I do worry what I will find when I start stripping the paint down to metal.

Thanks
 

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No question in my mind there. CUT IT OUT. I have cut out much better metal than that. As far as the ribs you speak of, they can be put in the metal with nothing more than a piece of tubing (pipe) and a shop press. They are also called cross brakes or embossments to stiffen the panel. A local sheetmetal shop could do that in a few minutes on a press brake if you cannot find replacment panels. I do that at work myself. I would also check the Hemming Motor news online for vendors, maybe Bills Speed Shop in Ohio. He has a large catologe of replacement sections. RB Obsolete in Washington may also be another source of replacement floor pans- there are soooo many out there to check. I have seen a lot of guys just use plain sheetmetal, but I like to stiffen it myself with the ribs. From my own experience, if you POR that, it will just peel away with more rust in a few years. A 41 Buick should have enough value to replace the floors properly. Sometimes, the right way actually ends up being the cheapest way to go. Just my opinions, there are some Pro's on this board that may have better input on this.
 

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Tow Chainer
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As you patch you will find it is worse than it looks. Take wire cup on your grinder to it and watch the holes open up. I'm in the same boat with my 54 dodge, and I've had to add more patch on both sides than I initially thought. No matter what you do fiber or metal get all the rust you can out. If you weld you may run into spots where it starts burning through bad due to thin metal. Good luck.

Check my journal for how much I removed so far on mine.

Added

The hole/patch on the passenger side now is twice that size. I'll put up more pics soon.
 

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Being a VW guy, I deal with a lot of floor pan rust. Replace it!!! No question about it. Cut it out and get new pans, if you can't find something original, look for something close. I cut out the rear pans in my '68 and welded in new ones in a day. It's definitely worth the time and effort to get it done right the first time! I'm sure your Buick has a frame, but my VWs are a flat pan chassis, so skimping in this area is NOT an option for me.
 
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