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Rust?  

 

Take a gander at this...  If you don't kill the rust, it will just get worse.  Welding may be best, but it is by no means necessary if done right.  I'd look at some of the underbody sealer and rust neutralizer/converter stuff Eastwood Co has as well.

 

http://www.hotrod.com/how-to/paint-body/1506-theres-more-than-one-way-to-fix-a-floor/

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18 or 20 gauge is pretty easy to work with. Obviously avoid galvanized if you're welding it, any bigger hardware store should have a piece of sheet metal that'll work. Nothing special required, I made a patch panel out of an old metal cabinet once. 

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