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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.




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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
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.


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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.
 

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Discussion Starter #4
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
 

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For real, thank you. I like this alot.

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

L
 

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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
 

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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!
 

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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
 

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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!!
 
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