Need help with floor pan install!

jonathanD · Poncho Master!

Need help with floor pan install!

4SPEED427 · A Poncho Legend!

Do you have the replacement pans already?

Do you have a mig welder, or if not, is one available for you to rent/borrow?

If so, you are ready to go. You can do pans yourself, it's actually a fun job. And you'll save a ton of money in the process. It takes a fair bit of time, but it's not a high tech job, and the best part is, it doesn't have to be perfect because almost nobody sees them.

jonathanD · Poncho Master!

Thanks Carl for the reply I do have a Lincoln 140 mug welder , and I have some gently used floor pans to put in, I'm just a little overwhelmed lol

4SPEED427 · A Poncho Legend!

Don't let it overwhelm you, it really is a fun task, I'm not kidding!

The pans you have, are they two sides, or is it one piece? Can you post some pictures of the floors in your car, as well as pics of what you are putting in? Shots of the top, bottom, sides etc? That will help with deciding where to cut your's.

Professur · Guru

First advice, Stacey David did floors on a Bronco on the show Trucks. Should be available on U-tube. Find it and watch it. Several episodes. Next ... take an ice pick or awl and attack your existing floor. Hit it hard. Anywhere where it leaves damage is too thin to leave behind. You can't weld to tin foil. Draw yourself some cut lines. Then crawl underneath and make sure you know where important things like frame rails, fuel and brake lines are. If you suspect you're going to cut them, drill marker holes upwards so you can see where they are from topside. Then get yourself something to cut with. A body saw, variable speed reciprocating saw, jig saw ... or (my preferred option) a 4.5" grinder with a cut off disk (DO NOT buy cheap disks). Dress yourself in appropriate protective gear and pick one straight line to start with ... and make your first cut. Then put the tools down, unplug anything electric, go to the fridge, take out a beer and open it, find a TV and park yourself in front of it for a couple of hours ... or the night. Then when your hands have stopped shaking and you're ready .. go finish the cuts and slap your replacement pan over the hole. Mark it for fit from underneath .. take it to your bench and trim it to fit. Weld in it like Stacey described in his video.

The first cut is the worst. Once you get past it ... it's just work. The first one ... that can be bad.

-- Edited by Professur on Friday 10th of June 2016 01:09:25 PM

norontcan · Canadian Poncho Superstar!

Jonathan - many of us less than professional guys have tackled this with some pretty decent results. Right now it seems like one gigantic chore- it isn't. Try and break it down into smaller tasks ( ie think of it as 1 small section at a time ) then tackle that section. As you complete a section give yourself a pat on the back, learn from what you accomplished and move on to the next section.

Lefty · Uber Guru

nothing beats saying i did it ,myself

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jonathanD · Poncho Master!

These are the pans I got, they came out of a 67 impala

Thanks for all the words of encouragement guys

4SPEED427 · A Poncho Legend!

Are you hoping to put them each in as pictured, in one piece? If so, that is more work than pieces but still can be done. Is the body bolted down, or loose on the frame?

jonathanD · Poncho Master!

i was planning on cutting them up and using as much of the original car as possible!

and the body is not bolted down at all

firstdancebridalcars · Addicted!

If useing a cutting disc make sure any glass is covered so the hot filings dont melt into the glass. Agree with Professur that first cut can be fun but take your time and it will work out.

4SPEED427 · A Poncho Legend!

Does the trunk pan you are putting in have the supports under it already? Can you post a picture of the bottom side of the trunk and the floor?

hawkeye5766 · Canadian Poncho Superstar!

Like others have stated,not all that hard to do,just time consuming. Measure and measure again, better to cut off not enough than too much. Start with the smallest sections first and by the time you get to the larger ones you'll have it down pat.

jonathanD · Poncho Master!

Carl Stevenson wrote:
Does the trunk pan you are putting in have the supports under it already? Can you post a picture of the bottom side of the trunk and the floor?

Yes the trunk pan does have supports

4SPEED427 · A Poncho Legend!

Oh, perfect. Lots less work to put in.

Now you just need to take a look at where it reaches to and start cutting your old pan out. As Jim said, just make sure you cut the opening for the pan too small to start. Easier to cut a bit more if you find you didn't cut enough. Next decision is butt weld (WAY more work) or overlap the new metal onto the car metal (LOT less work)

jonathanD · Poncho Master!

I think I'd do the overlap method, just because of time.

What I was thinking for the trunk pan was to remove the very back brace where the body mounts go then slice the pan in half and slide it into place, do you think that would work?

4SPEED427 · A Poncho Legend!

I think if you are willing to make it into a two piece pan, you can make it much simpler no matter where you "halve" it. The question is, do you need the whole thing or can you trim down the new pan and make it cover all it needs to on your car? Or is your trunk in the car to the point it needs everything the replacement pan offers?

bradkerbick · Veteran Member

Just finding my way around the site. What a supportive helpful group! Dale

Beaumont67SD · Guru

Once you start cutting, fitting & ready for the Mig - one good body hammer, helps.
My favorite is a original Snap-On BF-604, use it to tap the patch panel & original sheet metal together / ensuring a tight gap & easier welding.
- get a vintage forged BF-604 & not a new BF-604P / off ebay
www.faybutler.com/bodyhammer.htm