Found Rust Today
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Junior User
Joined: Dec 2011
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From: Dallas, TX
Found Rust Today
I began tearing out the carpet today and found what I expected, RUST 
Looks like new floor pans are in my future. I searched several threads and just wanted to make sure I'm clear on replacing the floor pans. When I cut the old pans out, how much overlap do I need for the lap welds? Also do the floor pans come per-drilled for spot welds will I need to drill them myself! If so what spacing drill size?
Carpet Out
The PO laid down a thick coat of bondo/fiberglass on the driver side, what a mess
Looks like new floor pans are in my future. I searched several threads and just wanted to make sure I'm clear on replacing the floor pans. When I cut the old pans out, how much overlap do I need for the lap welds? Also do the floor pans come per-drilled for spot welds will I need to drill them myself! If so what spacing drill size?
Carpet Out
The PO laid down a thick coat of bondo/fiberglass on the driver side, what a mess
Fleet Owner
Joined: Dec 2009
Posts: 20,678
Likes: 83
From: NorCal
I began tearing out the carpet today and found what I expected, RUST
Looks like new floor pans are in my future. I searched several threads and just wanted to make sure I'm clear on replacing the floor pans. When I cut the old pans out, how much overlap do I need for the lap welds? Also do the floor pans come per-drilled for spot welds will I need to drill them myself! If so what spacing drill size?
The PO laid down a thick coat of bondo/fiberglass on the driver side, what a mess
Looks like new floor pans are in my future. I searched several threads and just wanted to make sure I'm clear on replacing the floor pans. When I cut the old pans out, how much overlap do I need for the lap welds? Also do the floor pans come per-drilled for spot welds will I need to drill them myself! If so what spacing drill size?
The PO laid down a thick coat of bondo/fiberglass on the driver side, what a mess
You can either lap weld or butt weld. I prefer butt welding because I don;t have a flange roller or pneumatic flanging tool, plus it doesn't create a pocket joint where it can start corroding again.
Okay, you're lap welding.... Lay the cut out pieces on the new pans and trace around the silhouette. Then add the lap, about 3/4-inch is about right, to the trace. Floor pans do not come predrilled so either use a pneumatic punch, a hand punch, or a sharp 3/8-inch drill bit. Spacing should be about 2.5 inches on center, roughly about three fingers wide. Remember to use weld-thru primer and then seam seal both sides when completed. It wouldn't hurt to use POR-15 (or similar product) on the rest of the floors.
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Junior User
Joined: Dec 2011
Posts: 91
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From: Dallas, TX
Thanks for the info, I'm not a good enough welder for a but weld, so I will be going with the lap weld. Also I plan on coating everything very heavy with undercoating once it's finished. Thanks again
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