Footwells

When I do any bulkhead repairs I never take it off,can't see the point as you can get to everything you need with it still on (you may have to work upside down but you can still get to it).
Last one I did needed footwells,door pillars and around the vents welding but it was that bad even with the repair panels I had to fabricate some more as there was nothing to weld to,and I did all this with the bulkhead still on

the one on my s3 is like that, i looked at the door pillar and windscreen repair panels but they won't cover the drivers side rot so i got a used one to fit, then i will take the old one to someone who knows what they are doing and get a good repair and galvanise it, then keep it for when the replacement goes.

I have decided to take both wings off, pedals out etc.
When you weld in the new footwells do you weld inside along the seams and outside?

If you drill the spot welds out where there is any left then plug weld through the drill holes this is as strong as the original spot welds.
Can be seen on this pic of pillar.

But look up plug welding on the net

This pic on a full bulkhead rebuild shows the spot welds drilled out ,Bl***y loads of them.

Was that drilled out with just one spot weld drill bit or a box load?
Hadn't thought of welding it up like that. Can't see why it wouldn't be ok.
Also can you cold chisle the welds out? Thats how i've done it before (on a lorry).

I actually used an ordinary drill bit as old steel was being scrapped and the through hole in other half could be used for the button weld, some had to be split with chisel as access was to difficult.