I have cut a piece of 2mm for the floor in what was the passenger footwell. Right in front of the arch, it got plenty of mud and spray from the back wheel in its time. There was also a bracket attached to the floor which helped support the back seat. I cut the brackets off because there hasn't been a back seat in this thing for 25 years and there never will be again.
There is though still a strengthening beam under the floor following where the back seat bracket was. It steps down in level twice. The floor levels are all over the place here, it is impossible to just cut a flat piece to fit. Daihatsu put bead rolls in the floor and made it a complex profile to add strength, reduce the thickness of steel they had to use and reduce weight. Oh and to make it harder for me
I've used 2mm plate for this, just like on the other side. This time i went for a different approach and instead of putting two 90 degree bends along two edges I put one bend in diagonally. Still a few gaps to plug, the ones underneath can be built up with weld but the long triangular gap will need a bit making. Here they are with the passenger side first. I think I prefer the way I did it the first time but can't be arsed to change it now.
And from underneath which is what the mot tester will see

There are two small gaps to fill with weld and grind back (where the strengthening beam steps down) before fitting the floor..We don't want any mud traps for rot to get started in. This 2mm i have used is twice as thick as the original so will last longer as long as it is protected properly with paint.
Moving on to a small area I removed above one of the body to chassis mounts. There are ten of these mounts on the Fourtrak and are made of rubber and steel washers with a bolt through the middle. This one is right next to the back wheel so got a real splashing of salt and mud over the years. As with most 4x4's there is a ladder chassis made out of thick steel with the body mounted above. This differs from cars which have a monocoque construction where the chassis is integral with the body. Got a few 2mm bits to cut for this but shouldn't be a problem.
