Floor Pan Prep & Replacement

Next step remove the old, rusted floor pans & replace with new stamped panels.

Here's a shot of the right side passenger panel before cutting out.




















The original pans are spot welded onto a lip that is attached to the center tunnel & frame cross members. I was able to run a reciprocating metal cutting saw blade along the lip and get a fairly clean line.



Here's a picture of the driver's side floor pan cut out.


















I ground the spot welds down to bare metal...


















The old pan & replacement pan side by side. I used a pneumatic punch to make a series of 1/4 dia. holes approx. 1" apart around the lip of the new pan. I trimmed the pan to fit and spot welded it in place. You need to start in the middle of the hole on the existing frame lip and walk the weld out onto the new pan using a circular motion.

Right side done, left side fitted.


















After some consideration and consultation we decided to run a series of continuous welds along the top of the pan to further strengthen it.