The pan appears to be adequate. Classic Enterprises does a good job.

Making the patterns for the reinforcements.

.... not rocket science....

Cleaning out more of the rot......

The inner fits with the captive nut. Screws will come out when the welding is done

... baby steps....

So the captive nut idea wouldn't work with the main reinforcment box which bolts to the door hinge. It got too crowded inside the pillar and I didn't want to recreate the box.

To reduce the profile inside the pillar, we now go with "Captive bolts".....