Emilie Meyer
Installing a full floor pan is a complex process that requires careful preparation and a range of tools. Before beginning the installation, it is important to ensure that the underlying structures are protected from rust and that the floor is level to avoid any induced twists in the pan. It is also crucial to take accurate measurements and create a frame jig to keep everything in the correct location. When cutting the sheet metal, a plasma torch or a cutting wheel can be used, and spot welds should be drilled or pried up. Additionally, installing subframe connectors before cutting the old pan can help to prevent the car from tweaking during the installation. Once the new floor pan is in place, it can be welded in, and any necessary body work can be completed.
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What You'll Learn
Use a carpenter's level to check the flatness of the floor
To install a full floor pan, it is important to check the flatness of the floor. One way to do this is by using a carpenter's level. Here is a step-by-step guide on how to use a carpenter's level to check the flatness of the floor:
First, measure the room and find the centre point. Mark this spot with masking tape or an X. From this centre point, divide the room into four equal quadrants and mark the centres of each quadrant with an X as well. This will help you check the flatness of the floor throughout the entire room.
Next, you can use either a bubble or laser level on top of a long board laid on the floor. If you are using a bubble level, look at where the bubble rests. If the bubble is not within the middle lines, it indicates that the floor is not level. The further the bubble is to the side, the more sloped the floor is. For example, if the bubble touches the sides of the lines, it means the floor is off by about 1 inch (2.5 cm) per 4 feet (1.2 m). On the other hand, if you are using a laser level, set it up in the middle of the room and walk around with a tape measure or a graduated rod to make measurements.
Additionally, you can use a wooden plank with the laser level. Stand the plank up on one end and move it around the room, marking where the laser hits it. This will help you visualise any slopes or unevenness in the floor.
Another method is to use a round object, such as a ball, and place it on the ground. If the object rolls, it indicates that the floor is sloping and not flat.
By following these steps and using a carpenter's level, you can accurately check the flatness of the floor before installing a full floor pan. It is important to ensure the floor is level to prevent any issues with the installation and to ensure the final product is straight and stable.
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Prepare the car body by removing the old floor
To prepare the car body by removing the old floor, start by ensuring your car body is level. Use a carpenter's level or a laser level to check that your shop floor is flat. You can also use a couple of cheap spirit levels to do this. This is important because if your car body is not level when you install the new pan, any induced twist will remain after it's welded.
Next, if you plan to install subframe connectors or torque boxes, do this before you cut out the old pan. Subframe connectors will help to keep the car from tweaking as you put the new floor in. You can weld these to the floor pan, installing them in the front and back at the subframes, and then settle the new pan onto them.
Before cutting the old floor, test fit your new panel to make sure it will fit properly. Make notes so that you remember any adjustments once you walk away from the car. Mark the old floor pan with a crayon or pencil to indicate where to cut. You can use a plasma torch or a cutting wheel to cut away the old sheet metal. The cuts don't have to be perfect, as you can trim up any uneven edges later.
Drill or pry up any spot welds on the inner frame supports. Sometimes these welds can be difficult to find, especially if they are on rusted metal, so take your time with this step. Remove the old floor pan completely, and you will now be ready to install the new one.
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Cut the old floor and prepare the new panel
Before cutting the old floor, test fit the new panel to ensure a proper fit. Make notes on any adjustments needed, so you can remember them when you begin cutting.
When creating replacement panels, it is recommended to make the panel first and then cut away the old metal. This way, you only cut away what is necessary, and the cut will match your new panel. To do this, take a piece of cardboard and cut it roughly to fit the floor pan. Then, mark and cut it down so that it matches the original shape. Transfer the shape to the flat sheet metal and cut it out.
When cutting the old floor, use a plasma torch with a yardstick or wooden straight edge as a guide to achieve a clean cut. You can also use a body saw to make the cuts. The cuts do not have to be perfect, as you can trim up any uneven edges later. Before removing the old floor, drill out spot welds and spray a little cutting fluid or WD-40 on the cutting tip to keep it cool.
After cutting away the old metal, paint the underlying structures with a protective coating, such as Eastwood Frame Coating, to prevent rusting.
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Install subframe connectors and torque boxes
Installing subframe connectors and torque boxes is an important step in ensuring the structural integrity of your car. Here is a detailed guide on how to install them:
Firstly, it is recommended to install subframe connectors and torque boxes before cutting out the old floor pan. This will provide stability and reduce the risk of tweaking the car's structure while installing the new floor pan. If you're using USCT connectors, you can weld them to the front and back subframes, and then settle the new pan onto the connectors, welding them together.
When it comes to the connectors themselves, you have options like the USCT connectors or making your own. Some prefer to weld the connectors to the floor pan, while others stitch weld them to avoid excess heat. The more completely the connectors are welded to the floor, the more effective they will be in stiffening the car. If you decide to weld them, you can create 1" welds every few inches along both sides and fully weld the ends.
For torque boxes, you may need to do some tweaking to get them to fit right. You might have to cut and weld certain parts to ensure a nice, snug installation. Torque boxes were originally the factory's substitute for subframe connectors, providing a similar function of "tying it all together" but not in a straight line. If you install a solid weld in your subframe connector, you may not need torque boxes.
Finally, it is important to note that some sources indicate that while subframe connectors stiffen the car, they might cause issues over time by breaking spot welds due to the reduced flexibility. However, many people with a lot of miles on their cars with subframe connectors have not experienced these issues.
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Weld the new floor pan into place
When welding a new floor pan into place, it is important to ensure that the surface is level. Any twists or unevenness in the underlying structure will be locked in once the new floor pan is welded in place.
Before welding, it is recommended to test fit the new panel and make any necessary adjustments. Mark the area with a crayon or pencil and use a cutting wheel or plasma torch to cut away the rusty or damaged sections of the old floor pan. Drill holes or punch spot welds to separate the old pan, and cut the sheet metal of the new pan to size, shaping it to overlap the old pan by about one inch.
To weld the new floor pan into place, drill 5/16" holes into the new piece every 6 inches and plug weld it into place, filling the holes as you go. This will ensure a strong bond without causing distortion. You can also use MIG welding to fill the holes and seal the seams.
If you are using subframe connectors or torque boxes, weld them to the floor pan before settling the new pan into place and welding it up. This will provide additional support and help keep the car from tweaking during installation.
Finally, clean any weld-thru primer from the welded areas and apply a seam sealer to both sides of the panel before painting.
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Frequently asked questions
You will need a welder, body hammer, cutting wheel, wide sheet metal pliers, drill and bits, chisels, die grinder with sanding discs, straight edge, measuring tape, poster board, scissors, and a pencil/marker.
Before cutting the old floor, test fit your new panel. Make lots of notes so that you remember once you walk away from the car. Use a yardstick or other wooden straight edge as a guide for your plasma torch to get perfectly clean cuts.
Paint all underlying structures with Eastwood Frame Coating to protect them from rusting. Weld-thru primer is also a good idea.
Install them before you cut the old pan out. You can install them in the front and back at the subframes and then settle the new pan on the connectors and weld them up.
You can weld in cross supports, vertical and horizontal supports to keep the body rigid. You could also use four by fours from right to left across the front and back end of the body and support it on jack stands.
