Emilie Meyer
Fixing floor pans can be a complex process, often requiring welding and drilling, and it is therefore a job that is typically performed by auto body shops. The process can vary depending on the extent of the damage, with small holes allowing for patch repairs, while more extensive rust or rot may require a full panel replacement. The cost of such repairs can vary, with some opting to perform the work themselves, while others seek out speciality shops to ensure the work is done correctly.
Do auto body shops fix floor pans?
| Characteristics | Values |
|---|---|
| Difficulty | Not an easy fix |
| Cost | $2800 estimated for the project |
| Repair options | Patch repair, partial panel replacement, full panel replacement |
| Tools required | Spot weld cutting tool, hand-held electric drill, C-clamps, welder, rivets, seam sealer |
| Time | Two weeks |
| Additional considerations | Need to address rust issues, support the body while off the frame, find a specialty shop |
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What You'll Learn
Repairing floor pans without welding
Auto body shops can fix floor pans, but it is not an easy job. Floor pans are usually spot-welded in place, and removing them requires cutting out each weld individually with a spot weld cutting tool. This is a slow process, and care must be taken not to break the cutting teeth.
If you are repairing a floor pan without welding, there are several methods you can use. One is to use a structural adhesive, as is done in some new cars. This method requires no welding, but the floor pan will need to be cured in an oven. Another method is to use a patch repair, which can be done with a riveted patch panel. This is not a long-term solution, but it will get the job done.
If you are repairing a large area, you may want to use a full or partial floor panel. Before installing a new panel, it is important to clean both mating surfaces and test fit the panel several times. Once you are satisfied with the fit, clamp the panel into place and tack on a few welds to hold it in place. If you are not welding, you can use a rivet and seam sealer to hold the panel in place.
Another method for repairing floor pans without welding is to use a fiberglass mesh and resin. This method involves laying the mesh over the hole in the floor pan and then mixing and pouring resin into the floor pan to fill the hole. This method should be done in a well-ventilated area, as the fumes from the resin can be strong.
It is also possible to repair a floor pan using a latex and silicone mixture as a sealer, and then re-riveting the panels in place. This method does not require welding and can be accomplished by anyone.
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Repairing rusty floor pans
Inspection and Preparation:
Begin by thoroughly inspecting the floor pans for rust and rot. Identify the areas that require repair and determine whether you will need a patch repair, partial panel replacement, or full floor pan replacement. Clean the affected areas to remove any dirt, debris, or flaked rust. This can be done by sanding or using a wire wheel attached to an electric grinder. Ensure you wear the appropriate safety gear, including gloves and eye protection, during this process.
Choosing the Right Repair Method:
If the hole caused by rust is not too big, you can opt for a patch repair. This involves cutting a patch from a replacement panel or using a sheet metal welding plug to cover the hole. For larger repairs, you may need to replace a partial panel or the entire floor pan. Partial panel replacement involves cutting out the damaged section and welding or riveting in a new panel. If the rust damage is extensive, replacing the entire floor pan with a one-piece panel might be the best option.
Removing Spot Welds:
Most American-made cars have spot welds holding the floor pans in place. Removing these welds can be challenging and time-consuming. Use a spot weld cutting tool attached to a handheld electric drill set at low RPM to slowly cut through the welds. Center-punch each spot weld before cutting to prevent the cutter from wandering.
Installing the New Panel:
Whether you are installing a patch, partial panel, or full floor pan, test fit the new panel several times to ensure a precise fit. Clamp the panel in place using C-clamps or similar tools. If welding, tack weld a few spots to hold the panel in place, then step back and check the alignment before final welding. If using rivets, apply a bead of sealer or structural adhesive before riveting the panel in place.
Preventing Future Rust:
To prevent future rust, treat the repaired area with a rust converter, which chemically converts rust into a protective polymeric coating. Follow this with a coating of rust encapsulator, a sealing-type coating that prevents further rusting. You can also spray both sides of the repaired area with a zinc-rich primer for added protection. Additionally, consider using flat floor mats that allow water to drain off, as standing water can lead to rust.
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Cost of floor pan replacement
The cost of floor pan replacement varies depending on the extent of the damage, the labour rate of the shop, and the materials used.
If the hole in the floor pan is not too big, a patch repair can be done, which is a cheaper option. For larger repairs, a partial panel replacement may be necessary. If the rust damage is extensive, replacing the entire floor pan with a one-piece panel is recommended, which will be more costly.
The labour cost for floor pan replacement can range from USD 40 to 80 per hour, with the total time required for the job estimated at 12-14 hours. This includes taking out the interior, fitting and welding the new pan, and putting the interior back in. The cost of the actual pan can vary depending on the make and model of the car, but it can range from a few hundred dollars to over $1000.
For example, one person quoted $1300 for labour to replace both pans, undercoating, and patching the rear wheel well. Another person was quoted $5500 for a complete floor pan replacement in a 65 fastback, which included the cost of two full-length pans, torque boxes, toe boards, and other miscellaneous items.
It is important to note that floor pan replacement can be a challenging task, and it is recommended to seek a reputable company with experienced professionals to avoid further damage to the vehicle.
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Removing spot welds
Drilling:
- Before drilling, it is important to center-punch the spot weld to prevent the drill bit from "walking" off its mark. Use a spot weld drill bit with a sharp central point, and run it at a slow speed with lubrication.
- Start by drilling a pilot hole with a smaller bit (2mm or 3mm) to guide the larger 8mm spot weld drill bit. This technique will help you refine your drilling technique and make the process more manageable.
- When using a drill, be patient and allow the bit to slowly dig into the weld. It is crucial to work slowly and with low RPMs, whether using an electric or cordless drill.
Grinding:
- Grinding is an alternative method to remove spot welds. You can use an angle grinder or a die grinder with carbide bits to grind down the welds.
- When using a grinder, be cautious of the metal chips produced, as they can stick into your skin. Wear appropriate safety gear and consider using a grinder with a 'ball'-shaped tungsten die grinder bit to reduce the risk of metal chips.
Chisel:
- Another option for removing spot welds is to use a chisel. A long, sharp, bevelled chisel can be effective in popping the welds.
- If you have access to air tools, an air chisel is a good choice and will help you achieve faster results. However, be mindful of the noise produced when using an air chisel, especially in residential areas.
Spot Weld Cutter:
- A spot weld cutter is a specialised tool designed for removing spot welds. It uses less power than a drill bit of the same size and is highly effective in breaking the bond between the two panels.
- When using a spot weld cutter, drill a pilot hole first and then use the cutter to create a hole around the spot weld, separating the panels.
Remember that removing spot welds is a time-consuming and challenging process. Take your time, choose the appropriate tools and techniques, and consider practicing on a junk car or similar vehicle before attempting it on your own car.
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Supporting the body off the frame
Body Rotisserie:
Some people choose to use a body rotisserie to support the body while working on the floor pans. This method allows for easy access to all sides of the vehicle and can provide a stable platform for repairs. However, not everyone may have access to or want to invest in a body rotisserie.
Lifting and Supporting:
One approach to supporting the body is to carefully lift it and place it on supports. This can be done by hanging the body from the hood hinge holes or cowl supports in the front and using a brace or hoist in the rear. It is important to lift the body high enough to comfortably work on the floor pans and ensure it is securely fastened to prevent accidents.
Welding in Cross and Vertical Supports:
To maintain the rigidity of the body and prevent twisting when removing the floor pans, welding in cross and vertical supports is recommended. This method provides additional stability and can help ensure the body remains intact during the repair process.
Using Jacks and Four-by-Fours:
Another technique is to use jack stands and four-by-fours to support the body. By lifting the body little by little, you can place the four-by-fours at mounting points, providing a stable base. This method can be used across the front and back ends of the body to distribute the weight evenly.
Repairing or Replacing Floor Pans:
Before supporting the body off the frame, it is important to assess the extent of the damage to the floor pans. If the damage is limited to a small area, a patch repair may be sufficient. For larger areas of damage, a partial panel replacement may be necessary. If the rust damage is extensive, replacing the entire floor pan with a one-piece panel is recommended.
Safety Considerations:
Working on floor pans and supporting the body off the frame can be dangerous. It is crucial to exercise extreme caution to prevent injuries. Always wear appropriate safety gear, including gloves and eye protection. Ensure the vehicle is securely supported and immobilized before beginning any work.
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Frequently asked questions
A floor pan is the sheet metal that makes up the floor of a car.
Floor pans can suffer from rust and rot, especially in older cars.
Yes, but it is not easy. You will need to remove seats and interior fixtures, drill out spot welds, and cut out the old floor pan. You will also need to decide whether to use a patch repair, a partial panel, or a full panel replacement.
There are several ways to repair a rusty floor pan, including welding in patches of fresh sheet metal, using structural adhesive, or riveting and sealing. It is important to clean and treat the metal to prevent further rust.
The cost of repairing a floor pan can vary depending on the extent of the damage and the method of repair. Some auto body shops charge by the hour for labor, which can range from $45 to $70 per hour.
