Tiffany Haney
Replacing the floor pan of a 1967 Mustang can be a challenging task, as evident by several forum discussions on the topic. The process may involve cutting out the old floor and welding in a new floor pan, either as a full replacement or in sections. One key consideration is the structural integrity of the vehicle, as the floor pan contributes significantly to the car's structure. It is recommended to place strategic jack stands and bracing to support the car during the replacement process. Additionally, the fit of the new floor pan is crucial, and some trimming and adjustments may be necessary to ensure a proper fit. The use of clamps, screws, and welds are commonly mentioned techniques to secure the new floor pan in place.
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What You'll Learn
Removing the old floor pan
Step 1: Prepare the Car
Place the car on a secure and level surface, such as jack stands, to ensure stability during the removal process. It is recommended to remove as much weight from the body as possible to reduce stress on the frame. If the windshield is out, you can consider placing support underneath the car, especially if you plan to install the new floor pan through the windshield opening.
Step 2: Measure and Mark
Before cutting or removing any parts, take precise measurements of the old floor pan and its surrounding components. Mark the height of the old floor pan along the inner rockers to ensure the new pan aligns correctly. If you have solid rockers and plan to install a one-piece floor pan, you will need to remove the entire firewall, which is a time-consuming process.
Step 3: Cut and Remove
Using appropriate tools, carefully cut out the old floor pan, leaving as much original metal as possible. This process can be challenging, especially if the floor pan is rusty or damaged. Take your time and work methodically to avoid causing further damage to the car's structure.
Step 4: Clean and Prepare
Once the old floor pan is removed, clean the surrounding metal surfaces to bare metal. This step is crucial for ensuring a solid weld when installing the new floor pan. Remove any paint, grease, rust, or other debris that may interfere with the welds.
Step 5: Final Checks
Before proceeding with the installation of the new floor pan, inspect the surrounding structure for any damage or misalignment. Check the rockers, torque boxes, and firewall for any issues that may have been caused during the removal process. It is important to address any problems before installing the new floor pan to ensure a secure and proper fit.
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Installing the new floor pan
Installing a new floor pan in your 1967 Mustang is a complex process that requires careful planning and execution. Here is a step-by-step guide to help you through the installation process:
Preparation
Before beginning the installation, it is essential to ensure that your Mustang is properly supported. This is a critical step as the floor pan provides structural integrity to the vehicle. Place jack stands under the car to provide stability and ensure the vehicle is level. If your rockers are in good condition, you won't need to brace the car, but if you need to put rockers in, bracing is recommended.
Removing the Old Floor Pan
Start by carefully removing the old floor pan. Cut out the damaged sections of the floor and firewall, leaving as much original metal as possible. Be cautious when cutting around the frame support to avoid affecting the body of the car. Once the old floor pan is removed, clean and prepare the area for the new floor pan.
Fitting the New Floor Pan
Place the new floor pan into position, ensuring it fits snugly. You may need to trim and adjust the edges of the replacement sheet metal pieces, especially the front and rocker side flanges, to achieve a precise fit. Make sure the pan butts up against the frame sections, as they will need to be spot welded for support.
Securing the New Floor Pan
Use clamps and sheet metal screws to pull the new floor pan down tightly to the frame extensions. Tack weld the pieces in place, ensuring the fit and position are correct before making your final welds. You can also use a method suggested by another Mustang enthusiast, which involves drilling a hole in the frame rail extensions, inserting a long bolt with washers on each end, tightening it down, and then spot welding.
Final Adjustments
Check that the new floor pan is securely in place and make any necessary adjustments. You may need to rebend areas that are not formed correctly using a hammer. Ensure that the floor pan is flush with the surrounding structure and that there are no gaps or misalignments.
Additional Considerations
If you are installing a one-piece floor pan, it can be installed through the windshield opening or from below, but you must ensure that the driveshaft, cables, and other components are out of the way. Additionally, consider purchasing extended floor pans or "toe board" sections to reach higher up on the firewall, ensuring you are welding onto good metal.
Remember to take your time, work methodically, and always prioritize safety when working on your Mustang.
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Repairing the firewall
Step 1: Source the Correct Firewall Assembly
Ensure that you have the correct firewall assembly for your 1967 Mustang. A complete firewall panel is available from CJ Pony Parts, which includes the entire vertical panel up to the cowl and two toe board panels that attach to the floorboards. This product is designed for 1967-1968 Mustangs and requires modifications to fit convertibles.
Step 2: Prepare the Work Area
Before beginning the repair, ensure that you have a clean and well-lit work area. Gather all the necessary tools and safety equipment, such as gloves and eye protection. It is also recommended to have a copy of the 67 Mustang shop manual on hand for reference.
Step 3: Remove the Old Firewall
Carefully remove the old firewall, taking note of its orientation and any attached components. You may need to remove certain parts to access the firewall, such as the steering column, booster, coolant hoses, and blower motor. Label and set aside any removed components for reinstallation.
Step 4: Inspect and Prepare the Firewall Opening
Once the old firewall has been removed, inspect the firewall opening for any damage or corrosion. Ensure that the area is clean and free of debris. If there is any damage, make the necessary repairs before installing the new firewall.
Step 5: Install the New Firewall
Refer to the installation instructions provided with your new firewall assembly. Carefully position the new firewall into place, ensuring that it is properly aligned with the firewall opening. Attach the new firewall using the appropriate hardware and following the recommended torque specifications.
Step 6: Reinstall Removed Components
Reinstall any components that were previously removed, such as the steering column and booster. Ensure that all connections are secure and that there is no damage to any hoses or wires.
Step 7: Final Inspection
Once the new firewall is installed and all components have been reattached, perform a final inspection to ensure that everything is secure and properly installed. Test the vehicle to ensure that it is safe to operate.
Remember to take your time and carefully follow the procedures outlined above. Repairing the firewall of your 67 Mustang can be a rewarding project, but it requires attention to detail and mechanical proficiency. If you have any doubts or encounter complications, it is recommended to consult a professional or seek advice from experienced Mustang enthusiasts or forums.
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Trimming and adjusting the new floor pan
Trimming and adjusting a new floor pan for a 1967 Mustang can be a challenging task, but with careful planning and execution, it can be accomplished successfully. Here are some detailed instructions and considerations for this process:
First, it is important to assess the condition of the existing floor pan and the surrounding structure. If there is extensive rust or damage, it may affect the fitment of the new floor pan. Take measurements of the existing floor pan and the surrounding areas to ensure that the new floor pan will be the correct size and shape.
When preparing to install the new floor pan, it is recommended to place it where it will be installed and drill up through the floor panel, using the hole in the frame rail extension. Run a long bolt with washers on each end and tighten it down to draw the pan into place before spot welding. This will help ensure that the pan is securely positioned.
As you work with the new floor pan, trimming and adjustments will likely be necessary. The replacement sheet metal pieces may not align perfectly with the original mounting points, so be prepared to trim and adjust as needed to achieve a precise fit. This may include trimming the edges of the new floor pan to ensure a flush fit with the frame sections.
It is important to prioritize the fitment of the frame-to-floor sections first and then work outwards, making adjustments as you go. If the new floor pan needs to be bumped outwards to clear any ridges or obstructions, trim the outer edges accordingly and consider re-bending a new edge flange if necessary before welding.
Throughout the process, it is crucial to support the body of the Mustang to prevent any unwanted movement or twisting of the chassis. This can be achieved by using jack stands or a rotisserie, ensuring that the weight of the body is adequately distributed and supported.
Additionally, consider the sequence of tasks. Some prefer to replace the floor pan first and then address the firewall, as working on the floor pan can weaken the body. Others suggest starting with the toe boards, as they sit under the floor pan and can be challenging to access once the new pan is in place.
Finally, be mindful of the unique characteristics of your Mustang. If it has welded-in subframe connectors, for example, it may impact how you install a one-piece floor pan. Always adapt your approach to the specific needs of your vehicle.
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Welding the new floor pan
Welding in a new floor pan for your 1967 Mustang can be a challenging task, but with careful preparation and the right techniques, you can achieve a solid and durable result. Here are some detailed instructions and considerations for welding the new floor pan:
Preparation and Fitment:
Before welding, it's crucial to ensure that the new floor pan fits snugly and securely. Place the new floor pan where it needs to go and drill holes through the floor panel and the frame rail extension. Use bolts and washers to tighten it down, drawing the pan into place. This ensures the pan is securely positioned before welding.
Tack Welding:
Start by tack welding the new floor pan in place. Tack welding involves making small welds at various points to hold the pan securely before final welding. This allows you to make adjustments and ensure the fit is perfect before committing to full welds.
Welding Techniques:
When welding the new floor pan, use spot welding or rosebud welding for support. Spot welding involves welding through the frame sections for a strong bond. Rosebud welding is a type of spot welding that uses a rosebud-shaped electrode to create a wider weld area, distributing heat more evenly.
Overlapping and Sealing:
Some prefer to avoid overlapping the new pans with the old floor, creating a clean break between the two. However, others suggest that butting the two edges together is more challenging but can provide a better long-term outcome. Lap joints can trap moisture, so welding both sides prevents moisture buildup.
Welding Order:
It's recommended to work on one side at a time, ensuring the car is well-supported. Start with the frame-to-floor sections, then trim and adjust as needed to make everything fit. You may need to bump pieces towards the outside of the car to clear the frame rail, so trim the outer edges for a flush fit before welding.
Rust Considerations:
Every weld on a car has the potential to be a source of rust, so it's essential to keep as much of the original metal as possible. If you need to make patches, consider the impact on potential rust development.
Rocker Considerations:
If your rockers are in good condition, you won't need to brace them when installing the new floor pan. However, if you need to put rockers in, bracing is recommended to maintain structural integrity.
Final Steps:
After welding, you can POR-15 the welded areas and put in the seat risers, sealing the seams with a brushable seam sealer. Finish by spraying a couple of coats of underbody coating on all the welded areas.
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Frequently asked questions
There are a few methods to replace the floor pan of a 67 Mustang. One way is to use the screw method to pull the floor pan down to the frame extension. You can also use clamps and sheet metal screws to pull things together. Make sure you only tack weld things in place and get the fit and position in place before making your final welds.
One common challenge is the amount of damage to the subframe extension, floor pan patches, and floor, which may be badly rusted and sagging. It is also important to be careful with the tranny tunnel as it has a lot of 'beef' in it for structural integrity.
It is important to brace the car and place several strategic jack stands under it before cutting out the old floor, as the car may lose structural integrity. It is also important to repair the firewall first and trim the new floorpan to the original, cutting no more of the original than necessary.
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