I'd say you did a pretty fair job with the inner cowl panel. They never fit right from the get-go and need to be massaged to fit. Your cut and weld looks pretty decent and that's one way to deal with the ill-fitting panels.

On the lap joint on the floor, that would work, but you definitely need to get rid of the rust to make a good joint. Panel bond has been touted as a good method for that. I don't have experience with that and butt welded my floor patches. I suppose epoxy with intermittent plug welds would work too, but epoxy might tend to crack or let go, especially if the surface isn't completely clean (residual rust). Panel bond may be more forgiving. Cons of butt welding is it's a lot of work and you need to deal with warping that may occur if you get too impatient. The floor is a spot where it doesn't have to be spot-on as it'll be covered up.


Kevin
1951 Chevy 3100 work truck
Follow this saga in Project Journal
Photos
1929 Ford pickup restored from the ground up. | 1929 Ford Special Coupe (First car)
Busting rust since the mid-60's
If you're smart enough to take it apart, you darn well better be smart enough to put it back together.