[Alan F]

So, the next item on my agenda for my current project is to replace a partial right floor pan. I have not done this kind of work before but feel confident about it.

My plan is to cut the new patch panel down to a size that is a little larger than the size of repair needed. Then I would mark the floor and grind where the cuts are supposed to be I plan on screwing the new panel to the old panel to hold it in place. I would drill some holes to mark the corners of the repair. Then I was going to take a cutoff wheel or airsaw to cut through both panels. I was going to only cut enough where I can start tack welding the new panel in to the opening. My goal would be to end up having to remove the screws to remove the old piece and the new piece would be tacked in place. Then finish weld and grind the piece.

I'd appreciate any comments on my plan of work. Thanks.

Here's the new panel. Notice it's not welded where the toe panel rolls and meets the transmission tunnel.

Here's the area to be repaired. Sorry for the darkness.

Here's a floor shift hump that I'm going to install too.

 

[Kaizen]

That should work fine. You might actually be able to run some short beads instead of tacks on final weld due to the thickness and surrounding structure of the floor.

 

[CTblown67]

I just did mine and did them just about the exact same way you are describing, except I used an air body saw to cut threw both panels. After cutting threw sections a few inches long, I removed the scrap and put a tack in to keep the proper alignment. The first one I had done I cut all the way around without the tacks and had a hard time lining the new piece up afterwards due to the floor moving after the cut.

 

[myrusty66]

trying to post pic of mine....similar but you may find it easier.http://http://s1344.photobucket.com/user/myrusty66/slideshow/

 

[myrusty66]

link didnt work....i can email if you want to see

 

[Alan F]

Pat, your picture is perfect. That's about exactly the same repair that I have to do. One difference is that I'm going to cut my patch area to be as small as possible.

FWIW The replacement panel I purchased came from Sherman. I'm not impressed with it.

 

[myrusty66]

took a couple tries to get pic correct. i got my panel from ground up....not too bad. i left the back long and flanged to weld on top of the floor brace. also cut as close to rocker as possible. from the underside of car, where everybody can see it, it doesnt look like it has been replaced. i found it to be less welding and especially grinding....my least favorite thing to do lying on my back....lol

 

[Alan F]

I spent some time yesterday analyzing the plan and I came up with one small concern and that is how to deal with the seam where the floor pan meets the toe board. Part of the area that needs to be replaced overlaps that area. If I stick solely to my plan above, I would have an area where a single panel meets a double thickness. I have decided to cut the pan to replicate the seam.

Does anyone know if there are spot welds along that seam. I don't see any and am hoping it's just seam sealer, but seems improbable.

I'm going to dig in to it today.

 

[myrusty66]

yes, there are spot welds. that seam is part of original floor, then toe board welds to that. the replacement panel i used had that seam replicated in stamping, so i just cut out to the curve of toe board and fit the seam as close as possible to what was left on the tunnel. if you look close at my pic it should show it

 

[comara87]

Alan,
Where did you get your floor shift hump at, I cant seem to find one anywhere. Also is there specs where to cut and weld, My 66 was an auto and don't just want to half ass the install or cut any extra then needed.
Chris

So, the next item on my agenda for my current project is to replace a partial right floor pan. I have not done this kind of work before but feel confident about it.

My plan is to cut the new patch panel down to a size that is a little larger than the size of repair needed. Then I would mark the floor and grind where the cuts are supposed to be I plan on screwing the new panel to the old panel to hold it in place. I would drill some holes to mark the corners of the repair. Then I was going to take a cutoff wheel or airsaw to cut through both panels. I was going to only cut enough where I can start tack welding the new panel in to the opening. My goal would be to end up having to remove the screws to remove the old piece and the new piece would be tacked in place. Then finish weld and grind the piece.

I'd appreciate any comments on my plan of work. Thanks.

Here's the new panel. Notice it's not welded where the toe panel rolls and meets the transmission tunnel.

Here's the area to be repaired. Sorry for the darkness.

Here's a floor shift hump that I'm going to install too.

 

[Alan F]

Alan,
Where did you get your floor shift hump at, I cant seem to find one anywhere. Also is there specs where to cut and weld, My 66 was an auto and don't just want to half ass the install or cut any extra then needed.
Chris

Chris, I got the shifter hump or porch from GroundUp (www.ss396.com). They were THE original site sponsor and I've been buying from them since.

In an attempt to save some money (and use some money I had in my Paypal account), I bought the floor panel from Summit. It was dropped shipped from Sherman and it's a piece of junk. I'm glad this is just a hobby car and not a high dollar restoration.

The floor shift hump for '66-67 is different than the one you see in my pictures. Here's the listings from Ground Up: http://www.ss396.com/mm5/merchant.m...ode=chevellecamino&Category_Code=SHIFTERHUMPS

So, I got the floor pieces fitted. Here's the small square piece in the toe-board. I wanted to leave it looking like it was two pieces underneath. So, the strip I cut out is where they overlapped.


I've got a little trimming to do on the big piece at the rear. The sides and front are done and I'm happy with it. I'm going to punch some holes where the pans overlap and do plug welds. There was no seam sealer between the two pieces, just metal on metal with about a dozen little spot welds.

 

[comara87]

Thank you.

 

[mjminino]

Couldn't you just cut the new metal a little bigger than the piece being cut out then sit it on top and spot weld around it?? Wouldn't that be easier to do then matching the cut hole up exactly with the new piece?

 

[Alan F]

Couldn't you just cut the new metal a little bigger than the piece being cut out then sit it on top and spot weld around it?? Wouldn't that be easier to do then matching the cut hole up exactly with the new piece?

That's what I'm going to do with the big piece. I'm going to cut a little and weld the seam, repeat until done.

I fitted a smaller piece.

I'm working on preparing some other things that need welding too so I can do it all at once. Once I get it all ready, I will break out the welder.

 

[mjminino]

Please post pictures! I have an entire floorboard (cut off at the pillars) and I am going to have to figure out a way to cut the floor out as i don't need the entire floorboard.