Tiffany Haney
If you're looking to repair a 79 Corvette's floor pan, you've come to the right place. This process can be time-consuming and messy, especially with the sanding, but it's not a tough job. You'll need to decide whether to repair the floor pan yourself or hire a professional to do it for you. If you choose to do it yourself, you can use epoxy resin and fiberglass cloth to fix the floor pan. You'll need to tape a plastic bag to the bottom side of the floor and then lay down several layers of glass inside the car, followed by two layers on the bottom side. You can also use fiberglass mat and epoxy resin to repair the floor pan. If you decide to hire a professional, be prepared to pay by the hour, and the cost of materials.
| Characteristics | Values |
|---|---|
| Repair Materials | Epoxy resin, Fiberglass cloth, Fiberglass mat, MarineTex, Stainless steel screws, Caulking gun, Plastic spreader, Glas cloth, Polypropylene |
| Repair Process | Cut out rusted areas, Weld in steel patch panels, Sand, Grind, Drill, Use rivets, Apply epoxy resin, Spread epoxy with putty knife, Scuff, Smooth |
| Repair Considerations | Ensure correct materials for car, Address rust problem, Repair from both sides for strength, Use mixing instructions for epoxy, Seal with seam sealer |
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What You'll Learn
Using epoxy resin and fibreglass cloth
To repair a fibreglass floor pan in a 79 Corvette, you can use epoxy resin and fibreglass cloth. This method is ideal for fixing fibreglass objects, as the resin and hardener soak into the cloth and harden into the desired shape.
First, ensure you have the correct materials for your car. It is important to prepare the surface by removing any rust and cleaning the area. You can use a wire brush to remove rust, and a quality metal cleaner to clean the surface.
Next, cut the fibreglass cloth to fit the area you are repairing. Tape a plastic bag or cardboard to the bottom side of the floor to protect the underside. Then, lay down several layers of fibreglass cloth inside the car, followed by two layers on the bottom side.
Mix the epoxy resin with the hardener according to the instructions. Use a plastic spreader to apply the epoxy resin to the fibreglass cloth, ensuring that the cloth is saturated. You can also use a roller or brush to apply the epoxy, working it out to remove any air bubbles and ensure a smooth finish.
Allow the epoxy to cure completely before moving on to the next step. Once cured, you can sand or knock off any high points to create a smooth surface. You can then paint the repaired area to match the surrounding floor pan.
It is important to note that epoxy resin is not compatible with all types of fibreglass. It is recommended to use fibreglass cloth instead of a fibreglass mat, as the cloth can conform to the curves of the floor pan. Additionally, always test the epoxy resin on a small area first to ensure compatibility and follow the safety instructions on the product labels.
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Drilling holes and using rivets
As you are repairing a fibreglass floor pan in a 79 Corvette, it is important to note that this model used metal floor pans, unlike earlier models that had fibreglass floors. Therefore, to repair your floor pan correctly, you should cut out the rusted area and weld in steel patch panels. Simply fibreglassing up rust holes will not cure the rust problem and it will likely return.
If you do not have access to a MIG welder, you could instead drill holes and use rivets to repair your floor pan. One method involves using a fibreglass mount hole repair kit, which includes plates and rivets. You can spot plate over the oversized hole, rivet the plate to the fibreglass, and then drill your screw hole into the metal for a permanent fix.
Alternatively, you can repair the fibreglass and metal by riveting them together at the seam and also using glue. You can use epoxy resin, such as Evercoat epoxy, in the seam and stainless-steel screws to pull it together. After the epoxy dries, you can grind the screw off level with the nut. You may also want to add a coat of seam sealer to the seams to seal off any old sealer that has become brittle.
Before applying any epoxy, it is important to prepare the surface properly. One method involves using Metal Prep on the cleaned metal surfaces, although be aware that POR15 hardens to a surface similar to glass, so it needs to be removed to ensure the epoxy will adhere correctly. You can also cut some fibreglass cloth to fit the damaged area, embed it in epoxy, and use a plastic spreader to work out all the air and ensure the cloth is saturated.
Depending on the size of the hole, you can tape a plastic bag (such as a freezer bag) to the bottom side of the floor, and then lay down several layers of glass inside the car, followed by two layers on the bottom side.
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Sanding and preparing the surface
Before beginning the repair, ensure you have the necessary safety equipment, including eye protection, a respirator, and gloves, as the process may generate dust and debris. It is also recommended to work in a well-ventilated area or use a respirator with appropriate filters to protect yourself from dust and chemical exposure.
Start by inspecting the floor pan for any damage, including cracks, holes, or delamination. Identify the areas that require repair or reinforcement. If there is any existing repair material, such as old epoxy or filler, remove it using a grinder or sandblaster to create a clean, smooth surface for the new repair. This step ensures that the new repair material will adhere properly and creates a more consistent surface for the next steps.
Once the surface is clean and free of contaminants, it's time to prepare the area for the fibreglass cloth and resin application. Use a grinder or sandpaper to scuff and roughen the surface, creating a textured profile. This process helps the epoxy resin achieve a better mechanical bond with the existing floor pan. Pay particular attention to the areas surrounding the damage, as well as any edges or transitions. A thorough scuffing ensures a stronger and more durable repair.
After scuffing, it is important to remove any dust or debris generated during the process. Use a vacuum or compressed air to ensure the area is free of any loose particles. You can also use a tack cloth to capture any remaining dust, providing a clean surface for the next steps.
Before applying the fibreglass cloth and resin, it is essential to ensure the surface is free of any oils or contaminants that may inhibit adhesion. Use a suitable solvent or degreaser, following the manufacturer's instructions and safety guidelines, to wipe down the prepared surface. This step ensures that the epoxy resin will properly wick into the cloth and bond with the existing floor pan.
With the surface now prepared, you can move on to the next step of applying the fibreglass cloth and epoxy resin. Remember to work in a well-ventilated area and follow the manufacturer's instructions for the specific products you are using.
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Using a caulking gun to apply epoxy
To repair a fibreglass floor pan in a 79 Corvette, you will need to use epoxy resin with fibreglass cloth or mat. Epoxy resin is available in cartridges that fit into a standard caulking gun. This allows you to dispense as little or as much as you need, reducing waste.
Point the nozzle of the caulking gun at the area you wish to repair and gently squeeze the trigger to dispense the epoxy. Apply the epoxy in a smooth, even motion, ensuring that you cover the entire surface that needs to be repaired. You may need to use a plastic spreader or spatula to work the epoxy into the fibreglass cloth or mat and remove any air bubbles.
It is important to work quickly when using a caulking gun to apply epoxy, as the epoxy will begin to harden soon after mixing. Follow the manufacturer's instructions for the correct curing time and temperature. Once the epoxy has cured, you can sand or scuff the surface to prepare it for painting if needed.
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Repairing from both sides
To repair a fibreglass floor pan in a 79 Corvette, you will need to repair it from both sides for the repair to be effective and long-lasting.
First, you will need to prepare the area. Sand the area to be repaired to scuff it up, and ensure it is clean. If there is any old glue or epoxy, this will need to be removed. If there is rust, you will need to cut out the rusted area and weld in a steel patch panel.
Next, you will need to apply the fibreglass cloth and epoxy resin. Tape a plastic bag (a freezer bag) to the bottom side of the floor to protect the underside of the car. Then, lay down several layers of fibreglass cloth inside the car, and two layers on the bottom side. You can use a caulking gun or a plastic spreader to apply the epoxy resin and ensure the cloth is saturated. You can also use wedges to spread the metal away from the fibreglass to apply the epoxy.
Once the epoxy has cured, you can knock off any high areas and fair it flush to the mating surfaces. You can then paint the repaired area.
Finally, you will need to reassemble the floor pan. If your Corvette is like the 76 model, the floor pans are riveted together. You can use stainless steel screws and washers to pull the floor pans together, and then grind the screws off level with the washers. You can also use a rivet gun and stainless steel rivets. You may want to add a coat of seam sealer to the seams.
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Frequently asked questions
You will need fibreglass resin, a hardener, and fibreglass cloth. You may also need epoxy resin, a caulking gun, and stainless steel screws.
First, use a caulking gun to apply the epoxy resin to the floor pan. Then, lay down several layers of fibreglass cloth, ensuring that the cloth is contoured to the curves of the floor pan. Finally, allow the epoxy to cure and sand down any high points.
The cost of repairs can vary depending on the extent of the damage and the method used. Hiring a professional to repair the floor pan can cost around $640 for an 8-hour day, while purchasing the materials and doing it yourself may be a more cost-effective option.
