Marianne Martinez
Replacing the floor pan of a 1966 Mustang is a complex process that requires a range of tools and materials, including a grinder, welder, welding gloves, safety glasses, and primer. It is important to ensure that the new floor pan covers all rusty areas, especially up to the seat platform, and to use a good rust-protecting sealer to prevent future rusting. Some Mustang owners opt for a full floor pan replacement, which can be installed through the windshield opening or back window, while others choose to replace individual panels, which requires less welding and presents a lower risk of the body getting out of shape.
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What You'll Learn
The importance of removing rust
Rust is a common issue for car owners, especially for those with older cars. While it may seem like a minor issue, rust can cause significant damage to a car's body and structure if left untreated. Here are some reasons why it is important to remove rust from your car, especially when it comes to replacing the floor pan of a 1966 Mustang:
Preventing Further Damage
Rust is the result of oxidation, which occurs when the metal underneath your car's paint is exposed to moisture and air. Over time, a small rust spot can spread, causing more extensive damage to the car's body. By removing rust as soon as it is noticed, you can prevent it from spreading and causing more costly and time-consuming repairs.
Structural Integrity
The floor pans of a car, like the 1966 Mustang, play an important role in the structural integrity of the vehicle. The ribbing in the stamped floor pans provides strength and reinforcement to the car's body. If left untreated, rust can weaken the floor pans, compromising the structural integrity of the car.
Aesthetics and Resale Value
Rust spots can significantly impact the appearance of your car, making it look less appealing. Whether you plan to keep or sell your car, removing rust and giving it a fresh coat of paint can greatly enhance its aesthetic value. Additionally, a car without rust is generally worth more than one with visible rust spots.
Safety Concerns
Rust can also impact the safety of your car. If the floor pans are weakened by rust, they may not be able to withstand the weight of the driver and passengers, potentially leading to a collapse. Ensuring that the floor pans are free from rust helps maintain the structural integrity and safety of the vehicle.
Cost-Effectiveness
While repairing rust damage can be expensive, especially if you seek professional help, it is still more cost-effective to address the issue early on. If rust is allowed to spread, the damage may become too extensive, requiring the replacement of entire parts, which will be significantly more expensive than simply removing rust and applying a new coat of paint.
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Choosing between a full floor pan replacement or partials
If you are considering replacing the floor pan of your 1966 Mustang, you may be wondering whether to opt for a full floor pan replacement or partial replacements. Here are some factors to consider when making your decision:
Appearance
One of the benefits of a full floor pan replacement is the seamless appearance it provides. With partial replacements, you will have welded seams where the new panels meet the existing structure. If you are restoring your Mustang to its original condition, you may prefer the cleaner look of a full floor pan.
Structural Integrity
The floor pans of a unibody car like the Mustang contribute to its structural integrity. The ribbing in stamped floor pans provides strength, and replacing them with flat pieces of metal can compromise this reinforcement. A full floor pan replacement may be preferable to ensure the structural integrity of your Mustang.
Ease of Installation
Some Mustang owners have reported that installing a full floor pan is less work than welding multiple partial panels. With a full floor pan, you also have the flexibility to access the inside of the frame rails and make any necessary adjustments, such as straightening out jack flaws. Additionally, you can coat the inside of the rails with paint for added protection.
Cost
Full floor pans can be more expensive than partial panels. If cost is a concern, you may want to consider patching or replacing individual panels. Evaluate the extent of the damage and the cost of both options before making a decision.
Accessibility
When installing a full floor pan, you will need to consider how to get it inside the car. Some owners have shared that they installed it through the windshield or back window opening, especially if the car was completely stripped. Others have suggested that the full floor pan might flex enough to fit through the door.
In conclusion, both options have their advantages and considerations. If you are seeking a seamless appearance, improved structural integrity, and easier installation, a full floor pan replacement may be the preferred choice. However, if cost is a primary factor and the damage is limited to specific areas, partial replacements might be more suitable. Remember to assess the condition of your Mustang and make measurements before deciding on the best course of action.
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Welding and sealant techniques
Welding and sealing a floor pan in a 1966 Mustang is a complex process, but one that can be done at home with the right tools and preparation.
Welding Techniques
Before beginning any welding, it is important to ensure the car is properly supported and that you only cut one side of the floor pan at a time. Measurements should be double and triple-checked, and the new pan should be placed and held as tightly as possible to the existing floor. When welding, work in increments of 1 to 1.5 inches at a time, moving to a different spot to keep the metal from warping. You will still need to pound the metal down with a hammer to keep it tight to the old part of the floor.
Butt welds are the most challenging technique, and lap welds are easier to perform. Plug-welding is also a quicker and simpler option, but there are concerns about trapping moisture.
Sealant Techniques
Seam sealer is an important product to use when sealing a floor pan. It fills microscopic holes and small nooks and crannies in the welds. Eastwood's seam sealer is a good option, as it dries quickly, is paintable, and is flexible so it won't crack over time. 3M's brushable seam sealer is another option, as it is the same product that Ford uses and won't crack or peel.
Before applying seam sealer, the floor pan should be treated with a product like Eastwood's Rust Encapsulator or POR-15, which seals rusty parts. However, POR-15 does not adhere well to painted surfaces, so it is important to prepare the surface by sanding it down to bare metal. After treating with POR-15, a coat of epoxy primer can be applied.
Other products that can be used include Rustoleum red primer and plow paint, which is designed to keep plows from rusting.
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Drilling and cutting techniques
Drilling Techniques:
- Spot Weld Drilling: Use a spot weld cutter to drill out the spot welds along the toe boards, rockers, and frame rails. This will allow you to separate the old floor pan from the car's structure.
- Hole Diameter: When drilling holes for plug welds, a common diameter is 3/8". You can use a step drill bit or a pneumatic punch if clearance allows.
- Weld Spacing: The spacing of welds is important. Plug welds should be 2-1/2" to 3" apart, but this may vary depending on the area. Refer to a repair manual or replicate the spacing from the original panel.
- Butt Weld Drilling: When butt welding, drill holes near the seam line to access a hammer claw and self-tapping screw for panel alignment.
Cutting Techniques:
- Tracing and Cutting: Lay the new pan over the old one and trace an outline for butt welding. Remove the new pan and cut about an inch lower than the traced line. Cut out the old metal, leaving only the traced line.
- Precision: Measure multiple times before cutting. Use appropriate tools like a sawzall or cutoff wheels for accurate cuts.
- Transition Panels: When installing the new floor pan, you may need to cut out parts of the old floor to fit transition panels. Cut carefully, ensuring you don't cut through the frame rail.
- Rust Removal: Cut out and remove all rusty sections of the old floor pan. Match the cut sections with repro parts for welding.
- Overlap: When installing the new pan, allow for a 1-2" overlap with the old metal. This provides extra strength and can be welded using weld-through primer to prevent rusting.
Remember to always wear safety gear, including gloves and safety glasses, when drilling and cutting. Take your time, double-check measurements, and refer to repair manuals or professional resources for additional guidance.
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Tools and materials needed
The tools and materials you will need to replace a 1966 Mustang floor pan are:
- A sawzall or cutoff wheel to cut the old floor pan out.
- A drill to drill out the spot welds.
- A spot weld cutter.
- A grinder to clean up the welds.
- Welding equipment, including a welder (a MIG welder is recommended), welding gloves, a welding hood, and a hammer.
- Screws, including self-tapping screws and sheet metal screws.
- Primer, including weld-through primer.
- Sealant.
- Spectrum sludge for soundproofing and sealing against moisture.
- Silver panel adhesive to help against rust.
Some additional tools and materials that may be useful include:
- A vacuum to clean up loose material.
- A shop vac.
- A cut-off wheel grinder.
- A wire wheel.
- Safety glasses.
- A dynacorn full pan.
- A transition pan.
- Pop rivets.
- Torque boxes.
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