Starting my floor repairs

[Rattler]

I finally had some time to start tearing into the cars interior today. I removed all the carpet and pad so I could determine how much of the floor had to be replaced. I'm going to salvage as much of the original floor as possible so I just need to cut out any of the bad flooring areas and weld in replacement pieces.

Here's some pics of my progress so far.

carpet removed.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20001.jpg

Floor rusted out around floor support
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20002.jpg

Rusted areas and patches needed
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20005%20patches%20needed.jpg

I'll update with more pics as I go. ;)

[Ms Grumpy]

Looks like a little bit of work. But at least it looks like you don't have to replace the whole floor. Keep us informed on your progress.

[shadowgray396]

Looks like a bit of work, but repairable. I would check out the rest of the floor for thin spots. It migh be easier to put in a larger repair panel in then have to do it again down the road it the rest of the floor is questionable. Keep us posted on your progress.

Ray

[bolly]

my floor has approx the same areas for work, plus some at the passenger front area... 75% of the rest of the floor I repainted years ago and is still shiney


been thinking 1/4 floors, then 1/2's now a full floor.... and I'm only an amateur welder! LOL!!

will be watching to see what you do

[Mike 1972SS]

Until you sandblast the entire floor, you really don't know the hidden weak spots hiding under the rust. The floor in my Camaro didn't even look that bad until I sandblasted them. Now, I contemplating replacing the whole thing. It all depends on your goals, budget, etc. on what you decide to do with them.

Mike

[Rattler]

I've gone over the entire floor with a scraper and hammer. The rest of the floor is very solid. I was actually surprised to see that I had these holes. This is an Arizona car and we really don't run into too much of this out here.

I'm going to cut out the bad spot and see how large the patches will be. If they are larger then expected I can simply cut more out from my replacement floor. Have any of you used any of the dynacorn products? They seem to be the cheepest I've found and there's a shop local to me that has them. Check out this website. They've got some incredible deals! http://www.restorationperformance.com/servlet/the-136421/1964-dsh-67-Chevelle-Floor-Pan,/Detail

[Rattler]

Any of you ever try corroseal rust converter? I'm going to use it on the areas that are salvageable.

http://corroseal.com/images/corroseal-rust-converting-metal-primer-converts-rust.gif

[Highway Star]

My father used to use rust-mort. It worked pretty good.

Seems like you have your work "cut out" for you man. :D Sorry. :D

[Rattler]

lol! yes I do! I didn't have much time after work tonight, but I did manage to cut the bad areas out of the drivers rear. I may cut more just to make the shape easier to work with, but I do have all the rusty floor removed from this section.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20driver%20cut%20003.jpg

[Rattler]

Well I'm waiting for the drivers side floor pan to arrive so I started working on the passenger side since it wasn't nearly as bad. I've cut out the bad areas and cut my patch panels. It turned out very well for my first time doing any type of floor work. I'm happy with it so far. I will weld it all in once I get everything prepped and ready.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20patch%20passenger%20side%20002. jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20patch%20passenger%20side%20004. jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20patch%20passenger%20side%20001. jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20floor%20patch%20passenger%20side%20005. jpg

[1972convss454]

Until you sandblast the entire floor, you really don't know the hidden weak spots hiding under the rust. The floor in my Camaro didn't even look that bad until I sandblasted them. Now, I contemplating replacing the whole thing. It all depends on your goals, budget, etc. on what you decide to do with them.

Mike

X2 I thought the floors in my 72 were good until I got it back from the blaster. Kinda hurt my feelings. I went ahead and purchased a complete floor pan from RPC. They are a great company. I live in TN. Ordered it on Tuesday and it was at my house on Friday.

Progress looks great. Keep us posted.

[shadowgray396]

Looking good so far.

Ray

[shadowgray396]

Any updates on the floor project?

[Rattler]

Not yet.. should have my drivers side floorpan on Thursday and will begin welding everything this weekend. I was finding more and more that I didn't like about the cage so I cut everything out except the roll bar. I'm going to cut the roll bar out next so I can shorten it 1" and clean it up then re-install it at the same time.

[Rattler]

Picked up my floor pan today. Looks to be made well. I did notice that the stamping that runs from front to rear for factory wiring to lay into is stamped with 3 small lines rather then one large one so it's not going to match my existing perfectly, but it will do the job since this car is already cut up and tubbed. :D

new pan
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20new%20floor%20pan%20002.jpg

[Rattler]

Cut out the worst piece of flooring this morning.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20new%20pan%20001.jpg

Used part of it for a template
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20new%20pan%20002.jpg

Cut up the new pan
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20new%20pan%20003.jpg

Pan almost cut to fit. I still have more trimming to do
http://www.allenitllc.com/hotrods/chevelle/interior/floor/chevelle%20new%20pan%20004.jpg

[bolly]

Rattler, why use pieces of the new floor and not the complete pan?

[Rattler]

You always want to try and keep as much original metal as possible and only cut out what's rusted away. I cut back far enough to get to good solid metal so the two pieces can be butt welded together.

This is my first attempt at doing floors like this, but I learned it all from the internet and reading the good old muscle car mag. LOL

If you can find it the August 2010 "Floor Dance" article in the Muscle Car Review mag is top notch and incredibly educational.

[Rattler]

Well I manged to get the front drivers pan welded in. Figured I'd tackle the worst patch first hoping it can only get easier from here on out. I've still got some grinding to do, but it's going to work out well.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/driver%20front%20pan%20welded%20001.jpg

[bolly]

not too shabby Rattler!

how much time to weld that patch in? What type welder?

[Ms Grumpy]

Looks like you have had some experience with welding. I like watching the progress.

[Rattler]

not too shabby Rattler!

how much time to weld that patch in? What type welder?

I spent all day Saturday cutting the patch piece and about 6 hours on Sunday to weld it into place. I'm very new to welding on sheet metal so it took me a while to get the welder setting correct so I wouldn't burn through this stuff. I'm using a 110v Century wire feed with .030 wire with a 75/25 bottle hooked up to it.

[Highway Star]

That is one skill I'd like to pick up... Nice work, and all you can do is get better with experience. Keep us updated.

[Rattler]

No time during the week to get anything done, but I did manage to run out and apply a quick coat of rust converter/primer on that area.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/front%20pan%20primed.jpg

[bolly]

not bad at all Rattler!!

I'll be doing the same job here shortly, a friend suggested that if you're a great grinder you can grind the weld off and the patch becomes almost invisible

[Rattler]

Yes I'm sure you can blend the pieces right together if they are ground down flush. I'm still new to welding this stuff so I was afraid to grind too much down and make the welds weaker. Figured it's going to all be covered up anyway. :)

[grumpy]

Looks like it was in pretty good shape to begin with. Coming along nicely. Keep us posted on your progress

[Rattler]

Stayed home today and got some more work done on the passenger side of the car. LOL

http://www.allenitllc.com/hotrods/chevelle/interior/floor/passenger%20welded%20001.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/passenger%20welded%20002.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/passenger%20welded%20003.jpg

I should be done welding everything in tomorrow! wo0t!

[flash]

Show us a pic of your welder set up ,great job by the way.

[Rattler]

Thanks! I'm happy with the results so far.
It's a 110v century welder.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/welder.jpg

[flash]

I really like your welder cart ,I have a Lincoln similar to that without gas .I need to get the gas set-up for mine and learn how to weld .My welder is getting quite old and probably only 10 hours use on it mostly by my nephew who somewhat can weld.

[Rattler]

Haha! Thanks! yeah that good ol battery charger has all kinds of uses!

This project was extremely time consuming. Much more then I anticipated in the beginning, but it wasn't all that difficult. Just take your time and plug along each day. I ended up using over 2lbs of welding wire so I guess it was a ton of work. LOL

All patches finally done and floors are primed and ready for paint. ;)
http://www.allenitllc.com/hotrods/chevelle/interior/floor/floor%20primed%20001.jpg

[Rattler]

Well I got a nice thick hand brushed coat of oil based rustoleum down today. This floor should last a good long time now. ;)

http://www.allenitllc.com/hotrods/chevelle/interior/floor/floor%20painted%20001.jpg

[bolly]

good for another 40 years!!!

[Rattler]

Indeed! ;) When I'm all finished with the inside I'll jack it up and undercoat the bottom again as well.

[Rattler]

Well I got up this morning and figured out how I was going to cover the 4 speed hole in the tunnel. I cut a piece of aluminum sheet and just hammered on it until it formed the tunnel. Then I screwed it to the tunnel itself. This will be easy to remove if I ever decide to go back to a 4 speed "or me dream 6 speed" if I win the lottery. LOL
http://www.allenitllc.com/hotrods/chevelle/interior/floor/carpet%20and%20pad%20001.jpg

I'm working on the pad and carpet today as well. More pics to follow.

[Rattler]

I got all my carpet pad cut and installed. I started putting down the carpet and ran out of time today.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/carpet%20and%20pad%20002.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/carpet%20and%20pad%20003.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/carpet%20and%20pad%20004.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/carpet%20and%20pad%20005.jpg

[flash]

Looking good but I think you need to come to my house and practice some more on my floorpans .

[Rattler]

LOL I think I've had my share of welding floorpans for the next 10 years! *crosses fingers*

[Rattler]

Worked on the rear a bit today. Nothing much yet, but it will be all in black carpet to match the rest. Hopefully by next Friday I'll have it complete.

http://www.allenitllc.com/hotrods/chevelle/interior/floor/trunk%20wall%20001.jpg

[flash]

Looking good ,I need to sell mine or start working on it .Id rather sell as I dont have funds for another project now.

[Rattler]

Well I spent most the evening yesterday trying to figure out how I was going to upholster the back half of the car and finally came up with something.

I cut 3 panels of plywood today to cover the rear subframe section and covered them with more carpet pad and then black carpet. This left me with a gap between the front carpet kit that I had to deal with.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20001.jpg

I came up with an idea to make a seat of sorts to cover the area and blend the front into the rear of the car.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20002.jpg

Rear seat section assembled.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20003.jpg

Getting an idea of how it looks.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20004.jpg

Playing around with color options.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20005.jpg

[Rattler]

I installed a 2" foam pad over the top and covered it in soft black and red vinyl.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20006.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20007.jpg

All complete and in the car.
http://www.allenitllc.com/hotrods/chevelle/interior/floor/rear%20upholstery%20008.jpg

Now I just need to buy all my door panels and headliner to complete the interior. :D

[Rattler]

Finished bolting the seats, seat belts and shifter assembly in today. It all went together well. :D
http://www.allenitllc.com/hotrods/chevelle/interior/floor/upholstery%20complete%20002.jpg

http://www.allenitllc.com/hotrods/chevelle/interior/floor/upholstery%20complete%20003.jpg

[flash]

Looking good .