Hello all, I finally have a few pictures of my project and I am asking for advice on treatment of the floor pan corrosion near the doors on my ‘62 F100. I am hoping for spot repairs rather than an entirely new pan. Unfortunately I don’t have too much to share on the project as I am still waiting on the machine shop to finish the boring and heads refinished. The good news is that this is by far the worst corrosion on this truck with a small spot in the bed and the running board on the passenger side on the bed.

 

It depends on how you want to go at it. Do you want to patch many holes or few holes. How do the cab supports look?

 

Can support looks great from below but there may be a surprise. Is damage to the cab supports easily visible ? If so I think they are good.

 

That rust is severe and goes much deeper than the eye can see. Lots of work ahead.

 

Thanks for the info LMan, kinda what I suspected but hoping for some good luck

 

Kind of a tough call. I was in about your situation. I needed both front floor pans replaced, driver side front radius corner, pass side rear radius corner and pretty much the entire rear seam between the cab wall and the unibody bed. I also had to patch the cab mounts in several places. I opted to do it all individually as patch panels. I often think that I may have been better doing the entire floor. That said, the entire replacement floor does not match the original in a couple areas. The step ribs are wrong... also the transmission tunnel isn't correct for the "high" hump floor. For you another wrinkle is the shipping to AK.... Possibly better to ship the panels and not the whole floor. I would get the step, the step back wall, the rocker and the radius panel fort the A post and weld those together as a unit and then install it as one. Your truck is going to be super rusty inside those panels and I would say not worth saving.
I would be on the look-out for a parts truck near you. I know that is easier said than done. Mine has saved me lots over the years.
Lots of work ahead but it will be satisfying to see it come together.

 

I have the same issues with my 61 and have lots of patchwork ahead.

 

That is an excellent plan, I am going to continue with disassembly and will post when I complete or expose more damage. I may be able to get parts delivered via a friend driving hid RV up here next year, just have to wait until June! I think the panel order will be going out soon. All parts trucks I have seen so far are in far worse shape.

 

Unfortunately the Lizard is right. That is far worse than it appears, once you start cutting...
Check out my thread with pics from last spring!
https://www.ford-trucks.com/forums/1...body-work.html

The good news is that it's fixable. In fact, anything is fixable with enough time and MIG wire

 

DrCharles, thank you for posting that repair! I think I will be doing a few similar repairs. LizardMan warned me this is going to be worse than expected but your photos are a great resource. Thanks again to the FTE forum and all members!

 

I live in Washington State with a lot of rain and rust, so I removed my share. Your rust looks like a salted rust mixed in with basic iron oxide. My suggestion would be to get a die grinder or start with a drill motor and wire wheel or just a wire brush and dive in to get a feel for the rust and how deep the rust goes. Dr. Charles did some repairs I was impressed with he was able to get metal to stick together that looked like yours after cleaning. Anyways dive in and get a feel for the iron oxide.

 

Thanks Perry, I plan on that exactly and will post anything unusual. When I am underneath the truck, I don’t see any of the damage on the floor pan.