Replacing floor pans - Ford Muscle Forums : Ford Muscle Cars Tech Forum
 
LinkBack Thread Tools
post #1 of 10 (permalink) Old 05-14-2011, 08:22 AM Thread Starter
Subscriber
 
Join Date: Feb 2006
Location: Ellenville n.y
Posts: 221
Replacing floor pans

Floor Pan Replacement

I was getting ready to paint the rear floor and found some pin holes,I was going to make a patch and found more holes so replacement was in order. I take you along as I replace the floors on my fairlane.


I ordered a replacement floorpan from e-bay. My plan was to keep as much of my floor as possible. Here is a pic of the tools I used to do the job.


The first step was to measure the floor pan and cut off what was not needed. I cut the pan with the cutoff wheel.


I then drilled out the spot welds on rocker and drilled holes on the pan were it meets rocker for some plug welds. Now lay the new pan overtop of old pan and put a few screws in it to hold it in place.


Using a combo of air saw and cut off wheel with very thin blade cut though both the new pan and old floor tack welding as we go every 3 inches or so.


Here is a pic of the pan installed with tack welds and plug welded at rocker.The pan is butt welded a perfect fit.


After tack welding all the way around move back and fourth to keep heat down.I used .23 wire on this job and keep the heat setting on the lowest setting.


Here is a pic with the floor pan installed from the bottom.


After all welds are ground down I like to use brush on seam sealer and rub into seam both top and bottom.




Well there you have it,I spent about 5hrs with this repair with a little sanding and paint the seam will disappear...ED


Take your time. It's a very straight forward process. Just be sure to use small tack welds one at a time to prevent warping to panel from heat.




.

Last edited by FATNFAST; 05-14-2011 at 09:04 PM.
ford88 is offline  
Sponsored Links
Advertisement
 
post #2 of 10 (permalink) Old 07-08-2011, 06:59 PM
Registered User
 
Join Date: Feb 2005
Location: Decatur , G.A
Posts: 1,442
Re: Replacing floor pans

Great tech article bro.

I have a question, when you did this what do you mean by welding and cutting as you go ? did you cut both floors, then remove part of the old floor and weld the new floor in place all at once ?

Or did you cut both floors, remove the old floor then weld the patch in place ?

L
Quote:
Originally Posted by ford88 View Post
Using a combo of air saw and cut off wheel with very thin blade cut though both the new pan and old floor tack welding as we go every 3 inches or so.



63 Galaxie 500

PANEL BEATERS C.C - WE GOT GREASE UNDER OUR NAILS, NOT IN OUR HAIR
lgh1157 is offline  
post #3 of 10 (permalink) Old 07-09-2011, 05:12 AM
Registered User
 
Join Date: Mar 2010
Location: Chesapeak, VA
Posts: 235
Re: Replacing floor pans

Yeah I had the same question. I haven't seen it done but sounds like you're getting a perfect match by cutting both at the same time. Then does the existing floor beneath get stuck to the weld and require grinding to cut it loose? Great article by the way.

Steve
1971 Torino GT, 351C-4V, automatic, AC, 4.11 rearend, holley 750.
Duke351C4V is offline  
 
post #4 of 10 (permalink) Old 07-10-2011, 05:36 AM Thread Starter
Subscriber
 
Join Date: Feb 2006
Location: Ellenville n.y
Posts: 221
Re: Replacing floor pans

Duke & lgh1157 What you do as you cut though both floors go under and pull old floor away and and tack weld as you go from top.This way no weld hits the bottom of the old floor,This way when your done its a perfect butt weld...ED

ford88 is offline  
post #5 of 10 (permalink) Old 07-10-2011, 09:49 AM
Registered User
 
Join Date: Mar 2010
Location: Chesapeak, VA
Posts: 235
Re: Replacing floor pans

Awesome. Thanks!

Steve
1971 Torino GT, 351C-4V, automatic, AC, 4.11 rearend, holley 750.
Duke351C4V is offline  
post #6 of 10 (permalink) Old 07-10-2011, 04:52 PM
Registered User
 
Join Date: Feb 2005
Location: Decatur , G.A
Posts: 1,442
Re: Replacing floor pans

For real, thank you. I like this alot.

Hope i can make a nice small gap with a normal plug in grinder.

L

63 Galaxie 500

PANEL BEATERS C.C - WE GOT GREASE UNDER OUR NAILS, NOT IN OUR HAIR
lgh1157 is offline  
post #7 of 10 (permalink) Old 07-10-2011, 06:57 PM
Registered User
 
Join Date: Feb 2005
Location: Decatur , G.A
Posts: 1,442
Re: Replacing floor pans

So the verdict is , . . . . the air hacksaw is the way to go, i did it tonight with a grinder and standard cut-off wheel. It was ok, but not as tight as a hacksaw.

Im super stoked on this.

L

63 Galaxie 500

PANEL BEATERS C.C - WE GOT GREASE UNDER OUR NAILS, NOT IN OUR HAIR
lgh1157 is offline  
post #8 of 10 (permalink) Old 07-10-2011, 09:46 PM
Registered User
 
Join Date: Aug 2010
Location: Seattle
Posts: 1,015
Garage
Re: Replacing floor pans

WOW....

I did *ALL* the floors in my '66 Fairlane last summer... front, toe, rear under the seat, tranny tunnel you name it.

If I had done it this way I would have saved myself a ridiculous amount of time and effort.

I butt welded mine too but I cut the floor area I was working on first then spent all that time with fitment.

Your tech article didn't save me this time... but I know I'll do another floor and you can bet I'll be using your guidance and following your example.

Thank you and good luck on that Fairlane!


Current Project: 460 powered 1966 Fairlane GT/A 'vertible
Current Driver: 390 w/Death-O-Matic, '62 Galaxie 500 2dr Hardtop
Flip is offline  
post #9 of 10 (permalink) Old 07-24-2011, 11:21 AM
Registered User
 
Join Date: Dec 2006
Location: Las Vegas, NV
Posts: 922
Re: Replacing floor pans

Great write up.
I did this last year, replaced rear quarters, Rockers and rear floor pan in my 61 Sunliner all butt welds. The trick is to get the thinnest cut off wheel you can. Horrible Freight's 3" cut off wheels are 1/16" and measure out to.065" and the ones I used are .043". Doesn't sound like much but it is when it comes to butt welding. I'm sure you can find them at any good welding store, I buy mine from a vendor at the Hot August Nights swap meet every year.
I tried an air hacksaw but mine is a POS with no balls and was allways jamming up, you get what you pay for sometimes.
Several years ago I started to replace the floor pans in my 70 Mach 1 and did it the overlap way, did the drivers side and was so dissapointed in myself for not butt welding, functional but looked so unprofessional and I still needed to weld the under side and it would still look like crap I walked awayfrom the project and havent been back, trying to decide whether to leave it, try and salvage the hack job or tear it out and start new.
Mike
61Sunliner is offline  
post #10 of 10 (permalink) Old 02-02-2012, 05:52 AM
Registered User
 
Join Date: Mar 2008
Location: northern mn
Posts: 211
Re: Replacing floor pans

Big thumbs up ED!

That's some good old school stuff right there, I love it. Overlay and plug weld where it was pinch welded from the fact and butt weld everywhere else.

Very nice!!

Shaw Classic Auto Works.
Badger MN
northerndave is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ford Muscle Forums : Ford Muscle Cars Tech Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Forum Replies Last Post
New floor pans NewMuscle67 Falcon Pages 5 01-24-2009 07:55 PM
More Floor Pans Gydyup Mustang Pages (1965-1973) 2 01-06-2009 09:16 AM
67 Floor Pans Gydyup Mustang Pages (1965-1973) 11 12-03-2008 01:59 PM
Replacing 68 floor pans need advice Ralphw Torino Pages 3 12-02-2007 07:16 AM
Floor pans 59yblocker Fairlane Pages 1 06-07-2004 11:12 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome