Rusted floors

[Frankensteinz2]

Hey guys

So i went out and started removing my make shift metal floor pans to get to the actuals underneath today. After I was done I went into the house and cried for about 45 min. Once I wiped the tears away I went back out and began trying to figure out how i am going to put in new floor pans. I have researched forums on how to do this. However if i take out all the rust from the floor, and rust going up the side, i will have gaps between the floor pan and the existing good metal. What can I do about these gaps and how do i begin attaching a floor that is too small for the hole? I figure I can use some kind of metal to cover over these gaps but how thick, what kind, and what technique should I use. I am not a welder, and feel a little over matched but im not gonna give up. I have attached a couple of pics.

Thanks for the Help

Frankie

[zbane]

As to the portion of your question regarding what method to use for welding, I have no idea.

However, I do know that the metal you will need for the patches should be the same gauge or thicker than your replacement floorpans.

As to how you might go about making those patch panels, I would suggest getting some cardboard, lining up the panels you have (mock them in place somehow) and mark the cardboard to fit. From them, you'll have your templates for the various pieces.

And who said watching tv was bad...

[beandip]

Frankie, where did you buy the floor pans? If they are from Zed findings they are the first choice. You will now need to take the pans to a sheet metal shop and buy some metal at or near he same thickness. Hopefully you havent removed the floor on the other side of the car so you can make some measurements. As was mentioned by zbane, make cardboard pieces that will make up the difference between the floor and what is left of the car to attach the two parts. Use the pieces to cut the sheet metal parts. I would do one floor at a time. because you are going to need to take the car to a welder and the floors are part of the frame on these cars.

Buy a box of self taping sheet metal screws and attach the sheet metal parts that you have fabricated to the car. These are just temporary at this point, so just use enough to hold the pieces in place. Now do the same with the floor pans, fitting and bending all to blend to the shape needed. If you have cleaned all the surfaces well before assembly so the welder can just do his thing then , add more screws to hold everything securly and tight so your welder won't need to stop and mate the surfaces . His time is not cheep so do as much as you can your self. He cannot weld rusted metal so get it clean. I ended up with screws about every 5''. As my welder went along welding he removed the screws and filled the holes. I had over lapped the surfaces about 2'' to 3''. Now if you are involving much of the tranny tunnel you will need to have the transmission out of the car and also the brake and fuel lines away from where he is going to be welding.

Welding this sheet metal since it is so thin, is not a walk in the park, my welder , who is a certified craftsman. He used a TIG to do the job.

Judging from the limited pictures , you have a real project. I hope that this helps you. You will save a lot of money if you do all of the fitting and cleaning and making things ready for your welder. When I got the car back I cleaned and painted the bare metal with POR to prevent any rust and to seal.

Gary

[Frankensteinz2]

Yeah umm i was talkin to Charlie but I was in such a rush to get the floors in I went with MSA. I got the basic floors instead of the premium stamped, as I was not too concerned with the look under the carr as i do not plan to show it, just a daily driver. I have a welder in mind. I have removed both floor plans unfortunately. Hopefully the frame wont loose integrity, but i don't think that piece of ISH floor was doin much for support. I appreciate the pointers.

I'll post the finished product shortly. Thanks

Frankie

[Frankensteinz2]

Hey I have been cutting rust for the last 2 weeks and this is what i have to show for it. There are alot of gaps but i got some 16 gauge to fill that in hopefully it isn't to hard to fold. I also got rocker panels, rocker ends and wheel arch panels for the back as the rust had spread alot. Here are the pics.

[Frankensteinz2]

.................and done (for the most part), these are some pics of the driver's side, passenger side is going to take a little bit due to excessive rust at the fire wall and frame rail

now on to the rockers and wheel archs

frankie

[stevef1972z]

Great progress! Keep it up