Floorpan Install pt. 2

In Floors pt. 1 I managed to fabricate and tack in my first floor patch panel, as well as replace the rusted out body mount beneath. In this installment of the floors saga I will pick up where I left off and demonstrate my progress so far.

After the primer was good and dry, I set about the task of cutting out the passenger foot well. It was badly rusted and although I tried to get it out in one piece, things didn't exactly go as planned. The picture on the right is what I ended up pulling out of the car.

I started work by finish welding in the large patch I made in Floors pt. 1. The work wasn't too difficult but I did have to "chase" a lot of rust around with the welder. By this I mean that my welder would blow holes in the rusty steel as I welded to them. I thought I cut enough of the rusted floor board out but I guess not. It just goes to show that even though some metal looks OK it can still be rust-flawed

In any case, I got it all welded in, and as you can see here I primed over it. I welded the floor to the body mount through holes drilled directly above the mount. This is called plug welding.

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The body mount felt pretty solid. I was holding out hope that it wasn't so badly rusted that I would have to replace it. No such luck however, it was nasty and had to be removed.

Also note the toe-board. It's really rusty on the top right. I will have to cut it out and replace it too!

When you remove your body mounts make sure you support the car's body in the same position. You can run a scissor jack up under the door pillar or stack some 2x4 under it. Whatever you do you want to support it somehow so your doors don't sag when you cut the mound away from the inside of the door pillar.  

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The body mount must be unbolted from the frame in two places and then cut off the body at the spot welds.

Just like with the last body mount on this side the bolt was rusted in place. Unfortunately I twistedt the head off with a wrench. Out comes the torch and penetrant

Heat it with the torch and cool it with the oil. I like to use 3in1 because it doesn't start a big fire.

I then cut a slit in the bolt threads and used ratchet and a driver bit to ease it out. 

Once the body mount was removed I could go about making a new one. I went to a good friend's shop and took advantage of his metal break. After picking his brain a little I managed to knock up something that resembled a body mound.

I'll have to fit the body mount. I'm sure it will need to be finagled into place, but I think I can manage to do that.

I also welded in a small patch to make the passenger floorboard-patch a more square hole. I hope this will eliminate a little of the trouble when I make to patch for this portion.

There is much more to do but at least some of the work is done. In Floors pt. 3 I'll get my new body mount welded in, fabricate a big ol' patch for the floor over it, and tie up some loose ends with this project. The it's on to more rocker panel excitement! Thanks for reading and stay tuned.

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