On the driver side I have a hole where the floor pan meets the footwell right on the corner where it goes down to the door sill and between the door sill and the footwell along the depth of the seat in a few places. This would probably need just sheet metal work? The other hole is on the passenger side in the floor pan so I know I can fix that with a new floor pan.

 

When started my truck I ordered new floor pans from one of our sponsors. (not there fault, they sell what they can buy) I.M.O. they are junk and are not even close to origanal. I know there will be some flack for this statement and I don't care.
You are much farther ahead making your own floor boards. Maybe they won't have the exact shape but they will be much better than the crap i was sent. The ones i got are way too thin compared to the origanal. They didn't fit for beans either.
Buy a sheet of stock, a small plasma cutter and do it right or don't do it at all. You can pick up a little folder or metal brake and when your floor boards are done you will have something you can be proud of instead of tin pans that will rot out again.
For what you will pay for pans and shipping, ebay will be able to fix you up with a metal brake. A small plasma will fit on a credit card with out your wife knowing.
Your Ford truck deserves to have the best. Let the chevy guys pop rivet tin.

 

i used the new pans for a pattern and left about an inch of old metal for a flange to weld to. Aside from a few blow outs where the old metal was too thin i managed to mig weld a nice seam. i used seam sealer and undercoating on bottom side to prevent new rust

 

No way would you ever be able to make your own pans and have them look halfway decent or be as strong as the ones you can buy for 40 dollars.. yeah the majority of the replacment pans you buy are stamped in china and dont fit all that great, but thats a aftermarket part... its your job to make it fit and look right. THe pans I put in my truck were stamped crooked but was still able to make them fit, and look good, only took about 30 minutes of trial fitting and trimming..

You have to remove the old stuff.. otherwise whats the point in putting in new patches? It'll just rust out again in no time. Leaving the lip is a good idea, We used spot welds as well as a solid bead. Its more work but I know that its not going to tear out in a accident..rember the cab mount is mounted to the floor pan, and in a accident the mount of stress on that area is going to be extreme so dont cut corners, dont poprivet, etc etc, if you do your taking your life, and your passengers life in your hands.. not something I wanna do.

 

I think aftermarket floor pans are just fine. Better than a rusty floor. Or you could just make it stronger like I did...Rhino Line it.

http://i79.photobucket.com/albums/j1...y/IMG_0208.jpg

http://i79.photobucket.com/albums/j1...y/IMG_0202.jpg

 

I will not argue. Your own ability determines what you can and can't do. I made my pans because I have the ability to make them correctly like a craftsman would. If you can't do the same thing and you are happy with china pans warped and beat into your ford truck this is fine as well. Some guys are satisfied with pop riveting pans in. This is also fine for some. Do what ever makes you happy.

 

so if you don't mind me asking sir....what did you pay to rhino line the cab?

 

Or... you could find a california guy like me, who is parting out a truck and have him cut out the stock floor areas you need and ship them to you.

If you are interested PM me and I can email you pics and prices.

 

Broken40....I paid about $400 to have the inside and outside of the floor rhinolined.

 

I have nothing against that, nor you but, i can't even afford to redo the floor pans in my rig, let alone spend that kinda money to prevent the rust from coming back....it looks really good i don't doubt that.....if you got the cash right on i guess. lol

 

Yeah, it was expensive, but I figured money well spent if prevents rusted out floors again. I'm building my truck from ground up and had to replace the drivers side floor pan in the cab. Hopefully, it will last for a very long time.

 

i'm happy for you congrats on how far you've come it looks really good and i applaude you on your accomplishments.

 

I ordered mine from JC Whitney about 4 years ago and they went for around $40.