I was ready to start cutting but first I must take lots of photos and make as many measurements as I could because as soon as I cut the floor out I will have no nothing to work to.
The car came with a RH floor pan half but it had been chopped and changed so I had to bring it back to specification. I managed to get a new front quarter off a friend which I used to repair the pan I had but the seat runners were the wrong type but I’ll have to deal with these at a later date. I bought a new LH floor pan which was delivered ready for me to start work.
No grinder needed here, I just used a hacksaw to cut the outer rail and break off large sections of rusty metal without too much fuss. Working on one side at a time, large parts of the floor came out easy then i focused on the tricky bits. Using a wire brush and a bit of sand paper I could see the original spot and drill them out.
Then it was just a case of hammer and cold chisel to remove the rest of it.
Using the grinder with a wire brush i removed paint and rust, then on to a flapper disc I removed what was left of the spot welds and get bright metal on the area I was welding.
i also cleaned the lip on the new pan with the flapper disc ready for trial fit and trim. I was quite lucky because this pan needed minimal trimming and, using my measurements, lined up well first time.
After final cleaning I punched out holes along the edge of the pan with a metal hole punch ready for welding. I started with a gasless MiG welder but later moved to a gas mig and found it much easier. You can’t weld gasless without spending a lot of time cleaning the welds as you go. I plug welded the pan into position then seam welded along the edge, making sure I didn’t get the metal too hot to reduce the chance of warping.
The welds were cleaned up with flapper disc and grinding disc. Hint: let the grinder do the work, stops you getting over fatigued. Hint: wear ear defenders, goggles/face shield and dust mask, you’ll feel better for it!
The second half went much the same as the first
A quick spray of zinc primer helps keep the surface rust in check.