My build *UPDATE* 8/11/18

[SmashingPunkFan]

Moving along as scheduled this year, I'm very happy.

But I got to cutting the drivers floor out and am not sure how much transmission tunnel to leave as a lip... about an inch? 2 inches?
Plus any pictures would be amazing.
Thanks for all the support DC forum!  

[hemi-hampton]

Do you have the new floor. I like to leave a lip of a inch or 2 but some don't like any lip to overlap. Matter of opinion. LEON.

[PlainfieldCharger]

Do you have the new floor. I like to leave a lip of a inch or 2 but some don't like any lip to overlap. Matter of opinion. LEON.

Leon, what are the pros and cons of leaving a overlap?

[Troy]

If you overlap it's easier to weld and stronger than a butt weld. But the guy who owned one of my cars before me just left the jagged edge of the old pan hanging out the bottom which would have caught water and dirt and rusted out rather quickly. Leaving a large overlap could trap moisture between the 2 panels if it isn't sealed well.

I use the new pan as a template. Lay it on the old pan and trace it out so you know about where to cut the old one. You can cut just inside the line to leave room for trimming or well inside the line for overlap. I have a flanging tool that leaves a 1/4" step and, if welded on both sides, is very strong. However, it's a highly visible repair. It may be fine inside the tunnel where it's unlikely to be seen.

Troy

[SmashingPunkFan]

If you overlap it's easier to weld and stronger than a butt weld. But the guy who owned one of my cars before me just left the jagged edge of the old pan hanging out the bottom which would have caught water and dirt and rusted out rather quickly. Leaving a large overlap could trap moisture between the 2 panels if it isn't sealed well.

I use the new pan as a template. Lay it on the old pan and trace it out so you know about where to cut the old one. You can cut just inside the line to leave room for trimming or well inside the line for overlap. I have a flanging tool that leaves a 1/4" step and, if welded on both sides, is very strong. However, it's a highly visible repair. It may be fine inside the tunnel where it's unlikely to be seen.

Troy

Awesome. I figured about an inch would be ample. I'm not super concerned about seeing the repairs, not many will see underneath it. As long as it's strong, and resistant to rusting again

[Dino]

Why would you want to overlap a floor pan? It's so easy to make it fit edge to edge. Cut out the bad part and lay it on top of the new pan. Cut it and lay it in the hole. Doesn't get much easier than that.   

[SmashingPunkFan]

Why would you want to overlap a floor pan? It's so easy to make it fit edge to edge. Cut out the bad part and lay it on top of the new pan. Cut it and lay it in the hole. Doesn't get much easier than that.   

Resting weight? I wouldn't personally feel too safe riding on Just a buttweld, when it could rest some weight on the existing tranny tunnel. But that's just me

[Dino]

the butt welds would be more than strong enough to hold anything, but it's all academic because the pan will also be welded to the frame running underneath.

[Troy]

Yes, there's a lot of support in the floor pans! I butt welded the floors in my Challenger. Nothing moves!

Hey Dino, my floors came out in 100 pieces that were all mangled (used spot weld cutters, air chisel, cutoff wheels, etc.). I wish I could figure out how to remove them in one piece!

Troy

[Dino]

HA! Yeah that makes it a bit more complicated doesn't it? Think of it as a fun and entertaining puzzle!   

[SmashingPunkFan]

the butt welds would be more than strong enough to hold anything, but it's all academic because the pan will also be welded to the frame running underneath.

Awesome. Sounds good to me  this is just my first stab at front floorpan, and I want it done right

[SmashingPunkFan]

Found some rocker panel rust through... any suggestions? Definitely aiming to patch rather than replace.
What gauge steel should I use?

[hemi-hampton]

Pics of a similar repair I did. LEON.

[hemi-hampton]

Ended up patching under patch. Then faked the 4 spot welds. After painting looked factory like never repaired. LEON.

[SmashingPunkFan]

Pics of a similar repair I did. LEON.

Very nice. What did you spray on thats white?

[SmashingPunkFan]

Ended up patching under patch. Then faked the 4 spot welds. After painting looked factory like never repaired. LEON.

I love the detail.
What gauge steel did you use to replace?

[SmashingPunkFan]

https://youtu.be/hJjCwRR0n8Q

Heres my drivers side replacement in under 4 minutes

[hemi-hampton]

Pics of a similar repair I did. LEON.

Very nice. What did you spray on thats white?

Sprayed nothing that is white. Unless your talking about the bare metal your seeing. The rust was sandblasted to bare clean metal. In the last pic I used All Metal body filler that is silver in color. LEON.

[hemi-hampton]

Ended up patching under patch. Then faked the 4 spot welds. After painting looked factory like never repaired. LEON.

I love the detail.
What gauge steel did you use to replace?

Can't remember the gauge but probably around 22 guage. LEON.

[PlainfieldCharger]

https://youtu.be/hJjCwRR0n8Q

Heres my drivers side replacement in under 4 minutes

Thanks for sharing your video. Almost like watching a car show on TV... The whole car can be done next month.....

[SmashingPunkFan]

Ended up patching under patch. Then faked the 4 spot welds. After painting looked factory like never repaired. LEON.

I love the detail.
What gauge steel did you use to replace?

Can't remember the gauge but probably around 22 guage. LEON.

All metal? Is that a primer?
Did you apply anything inside the panel?
Thanks, Shaun.

[hemi-hampton]

Right after I wrote All Metal I wrote Body Filler. SO, The All Metal is Body Filler. Not Primer. I did not apply anything inside the panel. I did apply Weld threw primer under & inbetween my metal patches. LEON.

[SmashingPunkFan]

Right after I wrote All Metal I wrote Body Filler. SO, The All Metal is Body Filler. Not Primer. I did not apply anything inside the panel. I did apply Weld threw primer under & inbetween my metal patches. LEON.

I read too fast, sorry
Good stuff to know, thanks.

[lukedukem]

https://youtu.be/hJjCwRR0n8Q

Heres my drivers side replacement in under 4 minutes

You have a Mohawk? Nice

Luke

[SmashingPunkFan]

https://youtu.be/hJjCwRR0n8Q

Heres my drivers side replacement in under 4 minutes

You have a Mohawk? Nice

Luke

I do haha ever since I was 18. Life of being a skateboarder, and a car enthusiasts at the same time

Shaun